SEARCH · Engineering Papers

Results for “design and process development”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,027 records · Page 57

All sources NASA NTRS DOE OSTI

NASA NTRS2007

Development of a Reactor Model for Chemical Conversion of Lunar Regolith

Lunar regolith will be used for a variety of purposes such as oxygen and propellant production and manufacture of various materials. The design and development of chemical conversion reactors for processing lunar regolith will require an understanding of the coupling among the chemical, mass and energy transport processes occurring at the length and time scales of the overall reactor with those occurring at the corresponding scales of the regolith particles. To this end, a coupled transport model is developed using, as an example, the reduction of ilmenite-containing regolith by a continuous flow of hydrogen in a flow-through reactor. The ilmenite conversion occurs on the surface and within the regolith particles. As the ilmenite reduction proceeds, the hydrogen in the reactor is consumed, and this, in turn, affects the conversion rate of the ilmenite in the particles. Several important quantities are identified as a result of the analysis. Reactor scale parameters include the void fraction (i.e., the fraction of the reactor volume not occupied by the regolith particles) and the residence time of hydrogen in the reactor. Particle scale quantities include the time for hydrogen to diffuse into the pores of the regolith particles and the chemical reaction time. The paper investigates the relationships between these quantities and their impact on the regolith conversion. Application of the model to various chemical reactor types, such as fluidized-bed, packed-bed, and rotary-bed configurations, are discussed.

Hedge, uday↗

NASA NTRS2009

Development of a Reactor Model for Chemical Conversion of Lunar Regolith

Hegde, U.↗

NASA NTRS2007

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in normal gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-31) software. Quantitative model validation is ,provided by engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage_ Technology Demonstrator (STUSTD) program. The engineering checkout tests provide cryogenic tank self-pressurization test data at various heat leaks and tank fill levels. The predicted self-pressurization rates, ullage and liquid temperatures at discrete locations within the STUSTD tank are in good agreement with test data. The work presented here advances current CFD modeling capabilities for cryogenic pressure control and helps develop a low cost CFD-based design process for space hardware.

Lopez, Alfredo↗

NASA NTRS2012

Concurrent Mission and Systems Design at NASA Glenn Research Center: The Origins of the COMPASS Team

Established at the NASA Glenn Research Center (GRC) in 2006 to meet the need for rapid mission analysis and multi-disciplinary systems design for in-space and human missions, the Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) team is a multidisciplinary, concurrent engineering group whose primary purpose is to perform integrated systems analysis, but it is also capable of designing any system that involves one or more of the disciplines present in the team. The authors were involved in the development of the COMPASS team and its design process, and are continuously making refinements and enhancements. The team was unofficially started in the early 2000s as part of the distributed team known as Team JIMO (Jupiter Icy Moons Orbiter) in support of the multi-center collaborative JIMO spacecraft design during Project Prometheus. This paper documents the origins of a concurrent mission and systems design team at GRC and how it evolved into the COMPASS team, including defining the process, gathering the team and tools, building the facility, and performing studies.

McGuire, Melissa L.↗

NASA NTRS2016

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Prater, Tracie↗

NASA NTRS2016

Study of Material Densification of In718 in the Higher Throughput Parameter Regime

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this project is to characterize how heat treatment affects density and porosity from a microscopic point of view. This is performs using higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. Density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, and hatch spacing) and material consolidation (assessed in terms of density and porosity). The study also considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the higher energy parameter regime. Metallurgical evaluation of specimens will also be presented. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Cordner, Samuel↗

NASA NTRS2016

Flight Crew Integration (FCI) ISS Crew Comments Database & Products Summary

This Crew Debrief Data provides support for design and development of vehicles, hardware, requirements, procedures, processes, issue resolution, lessons learned, consolidation and trending for current Programs; and much of the data is also used to support development of future Programs.

Schuh, Susan↗

NASA NTRS2018

Development of High-Performance Solar Cells for the Jupiter and Saturn Environments

Many of the mission targets that NASA and the planetary-science community are interested in are located in deep space, in the 5-10AU range. This provides compelling motivation to develop solar cells and arrays that are highly efficient in low irradiance low temperature (LILT) environments. We give several examples of the iterative process our team has employed to develop cell designs that optimize the performance at LILT. We also provide results on advanced-architecture devices that have already demonstrated very high efficiencies in the Jupiter and Saturn LILT and radiation environments, specifically four-junction inverted metamorphic and triple-junction upright metamorphic solar cells, respectively.

Boca, Andreea↗

NASA NTRS2018

Composite Bonded Joint: Repair Development

This report documents the details of my work as a NASA KSC intern for the Fall Session from August 27th to December 14th, 2018. My efforts and contributions were with the Materials Science Branch, a staffed organization within the Laboratories, Development, & Testing (NE-L) Division of the Engineering Directorate. The principle responsibilities of the Materials Science group are to support the design, development, and operations activities for materials and processes with the purpose of providing unique solutions for flight hardware, ground support equipment, and customer requests. My role as an intern focused on assisting engineers in developing repair processes to mature bonded joint technology in support of SLS ? scale hardware. My primary goals for this internship were to become more familiar with composite materials and learn more about processes I was unfamiliar with, such as prepregs and out-of-autoclave processing. This project allowed me to learn new skills such as scarfing and curing composites. Additional goals I had were to learn more about NASA's laboratories and projects under development. This internship not only provided me with those experiences, but also allowed me to build relationships with inspiring engineers; a takeaway I will never forget.

Composite Materials↗

NASA NTRSDate not supplied

Feasibility Study to Dissolve Additively Manufactured Inconel 718 Support Structures

Additive manufacture (AM) component design face constrains due to support structure removal. Interior passages or delicate geometries require supports yet cannot be removed without compromising the design or complicating post-processing. A process was developed to dissolve metal AM supports where a sensitizing agent is applied post-build. During stress relief the sensitizing agent diffuses into the surface and alters the chemical composition of the top 100 to 200 μm. During an electrochemical dissolution process the sensitized region is susceptible to corrosion/dissolution and the etching reaction self-terminates once the sensitized region is dissolved. Support thickness varies from 80 to 200 μm, resulting in total dissolution or sufficiently weakened to facilitate removal. The objective of this project was to demonstrate a support structure dissolution process for IN718 components built using AM and to characterize the impact on mechanical properties, microstructure, and surface finish.

Omar R Mireles↗

NASA NTRSDate not supplied

NASA Developed High Temperature AM Alloys - Presenting NX810: An Additively Manufactured Oxide Dispersion Strengthened Alloy

Problem: Conventional materials and processing techniques limit the design and operating temperature of aerospace components. Proposed Solution: Develop a high temperature capable material that can be additively manufactured and can operate in temperatures above 2000°F (1093°C)

Timothy M. Smith↗

NASA NTRSDate not supplied

System Safety Analysis of Complex NASA Systems with Model Based Engineering

The emergence of model-based engineering is transforming design and analysis methodologies [5]. A recognized benefit of model-based engineering is the existence of a “single source of truth” about the system that becomes the authoritative source of data and information for designers, analysts, and developers. This promotes consistency and efficiency as the design emerges and can be used to further optimize the design. Integrating System Safety Engineers to the “single source of truth” will ensure that the outputs of their assessments and analyses are relevant to the design as it evolves. Use of an integrated system model enables near immediate evaluation of a design change as well as development of operational processes for risk assessment and communication. Such models can enable efficient and timely analysis of system hazards (e.g., hazard fault tree analysis and procedure simulations) and produce complete, accurate, and more consistent products (e.g., hazard reports and safety requirement evaluations). Therefore, an agency-sponsored team at Goddard Space Flight Center (GSFC) recently completed a System Safety Study of modeling and testing capabilities as part of a Model-Based Safety and Mission Assurance Initiative (MBSMAI). Using an existing model developed for reliability analyses [1], GSFC modeling and system safety experts performed system safety analysis/modeling and produced safety products. The team evaluated model-based feasibility to support System Safety Engineering, developed safety analysis modeling processes, and identified tool capability advancement/development needs. These study results indicate model-based engineering is valid and useable for System

Model Based Engineering↗

NASA NTRSDate not supplied

System Safety Analysis of Complex NASA Systems with Model-Based Engineering (REV B)

The emergence of model-based engineering is transforming design and analysis methodologies. A recognized benefit of model-based engineering is the existence of a “single source of truth” about the system that becomes the authoritative source of data and information for designers, analysts, and developers. This promotes consistency and efficiency as the design emerges and can be used to further optimize the design. Integrating System Safety Engineers to the “single source of truth” will ensure that the outputs of their assessments and analyses are relevant to the design as it evolves. Use of an integrated system model enables near immediate evaluation of a design change as well as development of operational processes for risk assessment and communication. Such models can enable efficient and timely analysis of system hazards (e.g., hazard fault tree analysis and procedure simulations) and produce complete, accurate, and more consistent products (e.g., hazard reports and safety requirement evaluations). Therefore, an agency-sponsored team at Goddard Space Flight Center (GSFC) recently completed a System Safety Study of modeling and testing capabilities as part of a Model-Based Safety and Mission Assurance Initiative (MBSMAI). Using an existing model developed for reliability analyses, GSFC modeling and system safety experts performed system safety analysis/modeling and produced safety products. The team evaluated model-based feasibility to support System Safety Engineering, developed safety analysis modeling processes, and identified tool capability advancement/development needs. These study results indicate model-based engineering is valid and useable for System Safety Engineering for NASA if adequate modeling processes and environment are established.

NASA↗

NASA NTRSDate not supplied

A Simulated High CO 2 Spaceflight Environment Increases Plant Preference for Ammonium as a Nitrogen Source.

The growth of crops to sustain astronauts will be critical to long-duration spaceflight missions. Carbon dioxide (CO 2 ) concentrations are very high in spaceflight cabin environments, often 5-10X the CO 2 concentration on Earth 1 . It is therefore crucial to understand how plants respond to elevated CO 2 (eCO 2 ). Nitrogen (N) is important for plant survival, though the effects of eCO 2 on plant uptake of different N forms remain poorly understood. Shoot nitrate assimilation may be reduced at eCO 2 due to a decrease in available reducing power through increased carbon fixation and inhibition of photorespiration 2 , suggesting that eCO 2 may increase plant ammonium preference (Figure 1). A deeper understanding of changes in plant nitrogen form preference in response to eCO 2 will inform nutrient optimization for future space crop production and wastewater processing system design requirements 3 in addition to developing future eCO 2 climate-ready crops.

nitrogen↗

DOE OSTI2022

Two-stage membrane-based process utilizing highly CO 2 -selective membranes for cost and energy efficient carbon capture from coal flue gas: A process simulation study

Membrane technology for CO 2 capture has become an attractive strategy due to its cost and energy efficiency and low materials costs. In the past decade, membrane-based process designs for post-combustion power plant CO 2 capture have been developed, utilizing existing highly CO 2 -permeable membranes with relatively low CO 2 /N 2 selectivity (<50), and have obtained reasonably economic carbon capture. However, few membrane-based process designs were proposed for moderate to highly CO 2 -selective membranes (CO 2 /N 2 selectivity of 50–300, and >300, respectively), which have vastly emerged in recent years, such as various facilitated transport membranes (FTMs). Herein, we proposed a two-stage membrane-base process design targeting economic carbon capture from coal-fired flue gas. This process design features the utilization of highly CO 2 -selective membranes for one-stage CO 2 enrichment to 95% dry-base purity in the first stage and recycle of the remaining CO 2 by a highly CO 2 -permeable membrane in the second stage, in order to achieve economic CO 2 capture with 90% capture rate and >95% CO 2 product purity. Through an integration-iteration membrane model and the Aspen Plus process simulation, a sensitivity study of operating pressures (feed and permeate pressures) and membrane properties (CO 2 permeance and CO 2 /N 2 selectivity) was conducted. Critical CO 2 /N 2 selectivity of 300–400 was found for the highly CO 2 -selctive membranes to meet the demand for cost and energy efficient results. The lowest possible membrane area of 4.8 × 10 5 m 2 and fractional energy of 19.3% were obtained, which is comparable to or even more attractive than reported membrane-based process designs. Here, this work provides a new membrane process design option for highly CO 2 -selective membranes and gives insights on the influence of membrane performance and operation condition.

42 ENGINEERING↗

DOE OSTI2023

Oak Ridge National Laboratory Security by Design: A Plant Design and Component-Based Approach to Technical Solutions to Insider and Outsider Threat

Security costs for nuclear reactors have been shown to rise over the lifecycle of a nuclear facility as new threats, security weaknesses, and the generic threat profile of the plant location change over time. This paper conducts a review of the technological gaps that currently exist in Security by Design (SeBD) based on the literature available and attempts to close those gaps through proposing technological constructs and processes that can integrate safety and security in the design process of a plant, with a primary focus on SMR technology. Under the new modular and mass manufacturing regime, where plant designs attempt to reduce costs with potential economies of scale and modular construction, the current SeBD definitions focusing on state level regulators are not considered adequate since the licensing stage is often too late in the design process to integrate the true cost savings of SeBD. Thus, this paper attempts to remedy the current logic in order to allow for continuous implementation of security alongside the development of the safety concept for the plant. If adopted within the design process the establishment of this type of technology will allow for a technological ecosystem to evolve that will imbed security concepts into the physical design of the components of the plant.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1982

The impact of distributed computing on education

In this paper, developments in digital computer technology since the early Fifties are reviewed briefly, and the parallelism which exists between these developments and developments in analysis and design procedures of structural engineering is identified. The recent trends in digital computer technology are examined in order to establish the fact that distributed processing is now an accepted philosophy for further developments. The impact of this on the analysis and design practices of structural engineering is assessed by first examining these practices from a data processing standpoint to identify the key operations and data bases, and then fitting them to the characteristics of distributed processing. The merits and drawbacks of the present philosophy in educating structural engineers are discussed and projections are made for the industry-academia relations in the distributed processing environment of structural analysis and design. An ongoing experiment of distributed computing in a university environment is described.

Utku, S.↗

NASA NTRS1991

Powder towpreg process development

The process for dry powder impregnation of carbon fiber tows being developed at LaRC overcomes many of the difficulties associated with melt, solution, and slurry prepregging. In the process, fluidized powder is deposited on spread tow bundles and fused to the fibers by radiant heating. Impregnated tows have been produced for preform, weaving, and composite materials applications. Design and operating data correlations were developed for scale up of the process to commercial operation. Bench scale single tow experiments at tow speeds up to 50 cm/sec have demonstrated that the process can be controlled to produce weavable towpreg. Samples were woven and molded into preform material of good quality.

Baucom, Robert M.↗