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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.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Utilization of simulation tools in the HL-20 conceptual design process

The role of simulations in the design of the HL-20, the crew-carrying unpowered lifting-body component of the NASA Personnel Launch System, is reviewed and illustrated with drawings and diagrams. Detailed consideration is given to the overall implementation of a real-time simulation of the HL-20 approach and landing phase, the baseline and experimental control laws used in the flight-control system, autoland guidance and control laws (vertical and lateral steering), the control-surface mixer and actuator model, and simulation results. The simulations allowed identification and correction of design problems with respect to the position of the landing gear and the original maximum L/D ratio of 3.2.

Jackson, E. B.↗
DOE OSTI2025

Pervaporative Dehydration of 2,3-Butanediol by Dense Poly(vinylidene fluoride) Hollow Fiber Membranes: Parameter Estimation, Process Design, and Technoeconomic Evaluation under Uncertainty

Pervaporation, combined with other separation processes, can effectively remove water from fermentation product streams, making it highly suitable for purifying alcohols like 2,3-butanediol (BDO). In this study, a dense poly(vinylidene fluoride) (PVDF) hollow fiber membrane module prototype was fabricated for BDO dehydration, achieving >0.2 LMH total flux and >95% BDO rejection. With a Markov chain Monte Carlo (MCMC) approach, Bayesian inference was used to quantify the uncertainty of the permeance parameters. A membrane cascade model was developed to scale up a process that purifies a preconcentrated BDO feed (70 wt %) to high purity (90 wt %). Through propagation of the uncertainty of the parameters and sensitivity analyses of the process variables, a cascade design was recommended. Despite data and model limitations, the framework enabled a reliable system analysis and economic evaluation, validated through tight confidence intervals in key process metrics, establishing the foundation for future applications of Bayesian methods in membrane-based processes.

Animal feed↗
DOE OSTI2020

Process design tools and techno-economic analysis for capacitive deionization

Capacitive deionization (CDI) devices use cyclical electrosorption on porous electrode surfaces to achieve water desalination. Process modeling and design of CDI systems requires accurate treatment of the coupling among input electrical forcing, input flow rates, and system responses including salt removal dynamics, water recovery, energy storage, and dissipation. Techno-economic analyses of CDI further require a method to calculate and compare between a produced commodity (e.g. desalted water) versus capital and operational costs of the system. In this work, we demonstrate a new modeling and analysis tool for CDI developed as an installable Matlab program that allows direct numerical simulation of CDI dynamics and calculation of key performance and cost parameters. The program is provided for free and is used to run open-source Simulink models. The Simulink environment sends information to the program and allows for a drag and drop design space where users can connect CDI cells to relevant periphery blocks such as grid energy, battery, solar panel, waste disposal, and maintenance/labor cost streams. The program allows for simulation of arbitrary current forcing and arbitrary flow rate forcing of one or more CDI cells. We employ validated well-mixed reactor formulations together with a non-linear circuit model formulation that can accommodate a variety of electric double layer sub-models (e.g. for charge efficiency). The program includes a graphical user interface (GUI) to specify CDI plant parameters, specify operating conditions, run individual tests or parameter batch-mode simulations, and plot relevant results. The techno-economic models convert among dimensional streams of species (e.g. feed, desalted water, and brine), energy, and cost and enable a variety of economic estimates including levelized water costs.

42 ENGINEERING↗
NASA NTRS1973

Design, process development, manufacture, test and evaluation of boron-aluminum for space shuttle components

A multi phase boron-aluminum design and evaluation program for space shuttle components was conducted, culminating in the fabrication of a 1.22 m (48 inch) x 1.83 m (72 inch) boron-aluminum compression panel capable of distributing a point load of 1555 kN (350,000 lbs) into a uniform running load at a temperature of 589 K (600 F). This panel was of the skin-stringer construction with two intermediate frame supports; seven unidirectional stringers varied in thickness from 5 plies to 52 plies and the skin was contoured to thicknesses ranging from 10 plies to 62 plies. Both the stringers and the skin incorporated Ti-6Al-4V titanium interleaves to increase bearing and in-plane shear strength. The discrete program phases were materials evaluation, design studies, process technology development, fabrication and assembly, and test and evaluation.

Garrett, R. A.↗
NASA NTRSDate not supplied

Design for Inspection: A Formalized Approach to Evaluating the Inspectability of Aerospace Structures Early in the Design Process

NDE engineers are often confronted with structural design choices that present challenges to meeting inspection requirements. These challenges at best increase the resources needed to design an inspection solution and, at worst, require resource intensive redesign of the structure. If the inspectability of structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. Therefore, there exists a need for a resource friendly formalized approach to gauge the inspectability of a structure. This paper proposes the use of a novel inspectability metric to meet this need. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. It provides a suite of simulation tests to interrogate the ability to find defects and the sensitivity to variability. The testing rubric is designed to maximize the coverage of the parameter space while minimizing the number of simulations needed. In this preliminary study, we will demonstrate how the inspectability metric is able to determine the inspectability of a structure as a function of changes in the structure’s design.

Peter Juarez↗
DOE OSTI2019

Process design and economics for production of advanced biofuels from genetically modified lipid-producing sorghum

This study evaluates the potential for making advanced biofuels from genetically modified (GM) lipid–producing sorghum. A biodiesel coproduction process is developed to extract, purify, and upgrade lipids to diesel fuel while carbohydrates are utilized for making ethanol through acid thermal pretreatment, enzymatic hydrolysis, and fermentation. To assess the advantages of coproducing biodiesel from GM–sorghum, process economics are compared to a cellulosic ethanol biorefinery receiving non-GM sorghum. Minimum ethanol selling prices (MESP) that reach a breakeven point after 30 years of service life are calculated as an economic index to compare the two processes. Results indicate that biodiesel coproduction improves the economics by lowering the MESP from 3.08/gal for the ethanol-only process to 2.46/gal. Sensitivity analyses reveal that increasing sorghum’s lipid content, increasing the lipid extraction efficiency, and reducing the solvent-to-solids ratio in lipid extraction columns are the most important process parameters to further enhance technoeconomics. Analyses indicate that a lipid content above 13 wt% (dry basis) or a biomass price less than 65/Mg (dry basis) will result in a 2014 ethanol wholesale price of 2.25/gal for the coproduction process.

09 BIOMASS FUELS↗
NASA NTRS1972

Design, processing, and testing of lsi arrays for space station

The design of a MOS 256-bit Random Access Memory (RAM) is discussed. Technological achievements comprise computer simulations that accurately predict performance; aluminum-gate COS/MOS devices including a 256-bit RAM with current sensing; and a silicon-gate process that is being used in the construction of a 256-bit RAM with voltage sensing. The Si-gate process increases speed by reducing the overlap capacitance between gate and source-drain, thus reducing the crossover capacitance and allowing shorter interconnections. The design of a Si-gate RAM, which is pin-for-pin compatible with an RCA bulk silicon COS/MOS memory (type TA 5974), is discussed in full. The Integrated Circuit Tester (ICT) is limited to dc evaluation, but the diagnostics and data collecting are under computer control. The Silicon-on-Sapphire Memory Evaluator (SOS-ME, previously called SOS Memory Exerciser) measures power supply drain and performs a minimum number of tests to establish operation of the memory devices. The Macrodata MD-100 is a microprogrammable tester which has capabilities of extensive testing at speeds up to 5 MHz. Beam-lead technology was successfully integrated with SOS technology to make a simple device with beam leads. This device and the scribing are discussed.

Lile, W. R.↗
DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Optimized aerodynamic design process for subsonic transport wing fitted with winglets

The aerodynamic design of a wind-tunnel model of a wing representative of that of a subsonic jet transport aircraft, fitted with winglets, was performed using two recently developed optimal wing-design computer programs. Both potential flow codes use a vortex lattice representation of the near-field of the aerodynamic surfaces for determination of the required mean camber surfaces for minimum induced drag, and both codes use far-field induced drag minimization procedures to obtain the required spanloads. One code uses a discrete vortex wake model for this far-field drag computation, while the second uses a 2-D advanced panel wake model. Wing camber shapes for the two codes are very similar, but the resulting winglet camber shapes differ widely. Design techniques and considerations for these two wind-tunnel models are detailed, including a description of the necessary modifications of the design geometry to format it for use by a numerically controlled machine for the actual model construction.

Kuhlman, J. M.↗
NASA NTRS1981

Reliability and the design process at Honeywell Avionics Division

The division's philosophy for designed-in reliability and a comparison of reliability programs for space, manned military aircraft, and commercial aircraft, are presented. Topics include: the reliability interface with design and production; the concept phase through final proposal; the design, development, test and evaluation phase; the production phase; and the commonality among space, military, and commercial avionics.

Bezat, A.↗
NASA NTRS1971

An optimal system design process for a Mars roving vehicle

The problem of determining the optimal design for a Mars roving vehicle is considered. A system model is generated by consideration of the physical constraints on the design parameters and the requirement that the system be deliverable to the Mars surface. An expression which evaluates system performance relative to mission goals as a function of the design parameters only is developed. The use of nonlinear programming techniques to optimize the design is proposed and an example considering only two of the vehicle subsystems is formulated and solved.

Pavarini, C.↗
DOE OSTI2025

Virtual Engineering: Python framework for engineering process design

Virtual Engineering (VE) is a Python software framework designed to accelerate the research and development of engineering processes that are fundamentally defined by multiple unit operations executed in series. VE supports a wide variety of different multi-physics models and integrates them to simulate a complete end-to-end process. To automate the execution of this model sequence, VE provides (i) a robust method to communicate between models, (ii) a high-level, user-friendly interface to set model parameters and enable optimization, and (iii) an overall model-agnostic approach that allows new computational units to be swapped in and out of workflows. Although the VE framework was developed to support the biochemical conversion of biomass to fuel, we have designed each component to easily accommodate new domains and unit models.

09 BIOMASS FUELS↗
DOE OSTI2021

Human-Centric Lighting: Foundational Considerations and a Five-Step Design Process

At its best, human-centric lighting considers the visual and non-visual effects of light in support of positive human outcomes. At its worst, it is a marketing phrase used to healthwash lighting products or lighting design solutions. There is no doubt that environmental lighting contributes to human health, but how might one practice human-centric lighting given both the credible potential and the implausible hype? Marketing literature is filled with promises. Technical lighting societies have summarized the science but have not yet offered design guidance. Meanwhile, designers are in the middle, attempting to distinguish credible knowledge from that which is dubious to make design decisions that affect people directly. This article is intended to: (1) empower the reader with fundamental understandings of ways in which light affects health; (2) provide a process for human-centric lighting design that can dovetail with the decision-making process that is already a part of a designer's workflow.

60 APPLIED LIFE SCIENCES↗
NASA NTRS1974

Automation of the aircraft design process

The increasing use of the computer to automate the aerospace product development and engineering process is examined with emphasis on structural analysis and design. Examples of systems of computer programs in aerospace and other industries are reviewed and related to the characteristics of aircraft design in its conceptual, preliminary, and detailed phases. Problems with current procedures are identified, and potential improvements from optimum utilization of integrated disciplinary computer programs by a man/computer team are indicated.

Heldenfels, R. R.↗