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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 NTRS2007

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM. During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90 percent random fiber currently used in small approx.100 W Stirling space-power convertors-in the Reynolds Number range of interest (50 to 100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6 to 9 percent; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators.

Tew, Roy↗
NASA NTRS2021

Supersonic Transport Optimization to Mach 4

Commercially viable supersonic transports require solution spaces to a longish list of serious issues including high drag, heating, emissions, costs, weights, acoustics, etc. Report addresses potential approaches to these issues including drag reduction, flow control, propulsion/ fuels/energetics, and synergistic frontier aircraft configurations across the board proffering large increases in lift to drag ratio.

Dennis M Bushnell↗
NASA NTRS2026

Manufacturing and Scale-Up of Natural Fiber Composite eVTOL Propeller Skin and C-Channel

This report presents the manufacturing and scale-up of natural fiber composites for aerospace applications, conducted within NASA’s Convergent Aeronautics Solutions portfolio to advance aircraft capabilities and efficiency. The effort focused on the development and demonstration of two proof-of-concept articles, an Electric Vertical Take-off and Landing (eVTOL) propeller skin and a C-channel, produced through an iterative design and process optimization approach. Best practices and guidance on addressing key challenges with bio-based composite materials and manufacturing is provided. Ideally suited for non-load-bearing structural components, these emerging materials offer potential for weight reduction, vibration damping, noise mitigation, interference-free communication, and cost savings, without compromising the performance of safety-critical primary structures.

Natural fibers↗
NASA NTRS2016

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

Low Technology Readiness Levels (TRLs) and high levels of uncertainty make it challenging to develop cost estimates of new technologies in the R&D phase. It is however essential for NASA to understand the costs and benefits associated with novel concepts, in order to prioritize research investments and evaluate the potential for technology transfer and commercialization. This paper proposes a framework to perform a cost-benefit analysis of a technology in the R&D phase. This framework was developed and used to assess the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. Following the definition of a case study for a cryogenic tank cylinder of specified geometry, data was gathered through interviews with Subject Matter Experts (SMEs), with particular focus placed on production costs and process complexity. This data served as the basis to produce process flowcharts and timelines, mass estimates, and rough order-of-magnitude cost and schedule estimates. The scalability of the results was subsequently investigated to understand the variability of the results based on tank size. Lastly, once costs and benefits were identified, the Analytic Hierarchy Process (AHP) was used to assess the relative value of these achieved benefits for potential stakeholders. These preliminary, rough order-of-magnitude results predict a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Compared to the composite manufacturing technique, these results predict cost savings of 35 to 58 percent; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The AHP study results revealed that decreased final cylinder mass and improved quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Ivanco, Marie L.↗
NASA NTRS1981

Adaptive Finite Element Technology in Integrated Design and Analysis

An assessment of the potential impact of adaptive finite element technology on the analysis part of the aircraft structural synthesis process is presented. The main conclusion is that adaptive application of the p-version of the finite element method based on indirect error estimation procedures results in substantial cost reduction and increased reliability of the computed data. Adaptivity based on direct a posteriori error estimation has the potential for additional savings.

Szabo, B. A.↗
NASA NTRS1996

Hypercars: The next industrial revolution

The auto industry -- one-seventh of the GNP, and the highest expression of the Iron Age -- is about to trigger the biggest transformation in industrial structure since the microchip. Ultralight cars molded from net-shape advanced composites can be several-fold lighter than present steel cars, yet safer, sportier, and more comfortable, durable, and beautiful. Modern hybrid-electric drives boost efficiency approximately 1.3-1.5x in heavy steel cars, but approximately 5-20x in ultralight, very slippery plafforms. Synergistically combined into ultralight-hybrid 'hypercars,' these elements can yield state-of-the-shelf family cars that average 150-300+ mi/gal -- twice that with state-of-the-art technologies -- yet can also be superior in all other respects, probably including cost: carbon-fiber monocoques can actually be cheaper to mass-produce that steel unibodies. Designing cars more like aircraft and less like tanks requires not only an approximately 400-500 kg curb mass and very low air and road drag, but also an aerospace philosophy of engineering integration. Mass, cost, and complexity turn out to compound with heavy hybrids but to decompound with ultralight hybrids, owing partly to radical simplification. Excellent aerodynamics, preferable including advanced techniques for passive boundary-layer control, will be the key to successful design integration. Transforming automaking is a competitive and environmental imperative, could form the nucleus of a green industrial Renaissance, and would enhance national security by, among other things, saving as much oil as OPEC now extracts. However, this transformation faces serious cultural barriers. For example, hypercars will be more like computers with wheels than like cars with chips -- they'll have an order of magnitude more code than today's cars -- but Detroit is not a software culture. Just the transition from stamped and welded steel to integrated and adhesive-joined synthetics is difficult enough. Nonetheless, hypercars are rapidly heading to market in the late 1990s, because approximately 25 current and intending automakers are eager to capture their potentially decisive competitive advantages -- including order-of-magnitude reductions in product cycle time, tooling cost, assembly effort, and parts count. Hypercars will succeed, and may well sweep the market, not because of mandates or subsidies, but because of manufacturers' quest for competitive advantage and customers' desire for better, smarter cars.

Lovins, Amory B.↗
NASA NTRS1973

Delta's inexpensive, reliable, and versatile third generation upper stage

The need for larger diameter fairings to encapsulate spacecraft designed to use Delta's increased lifting capabilities resulted in hammer-head design configurations that would have unaccepably degraded vehicle flight characteristics. This situation led to the development of the Straight Eight configuration. The towed mode arrangement for the second stage negated the requirement for the engine compartment structure, thus establishing the potential for an improved packaging of the hydraulic and pneumatic systems. Therefore, with cost reduction and reliability improvement objectives, a second stage propulsion system improvement program was initiated. The paper will describe these improvements and their system benefits.

Bonnett, E. W.↗
NASA NTRS1979

Cost comparisons for the use of nonterrestrial materials in space manufacturing of large structures

This paper presents results of a study sponsored by NASA to evaluate the relative merits of constructing solar power satellites (SPS) using resources obtained from the earth and from the moon. Three representative lunar resources utilization (LRU) concepts are developed and compared with a previously defined earth baseline concept. Economic assessment of the alternatives includes cost determination, economic threshold sensitivity to manufacturing cost variations, cost uncertainties, program funding schedule, and present value of costs. Results indicate that LRU for space construction is competitive with the earth baseline approach for a program requiring 100,000 metric tons per year of completed satellites. LRU can reduce earth-launched cargo requirements to less than 10% of that needed to build satellites exclusively from earth materials. LRU is potentially more cost-effective than earth-derived material utilization, due to significant reductions in both transportation and manufacturing costs. Because of uncertainties, cost-effectiveness cannot be ascertained with great confidence. The probability of LRU attaining a lower total program cost within the 30-year program appears to range from 57 to 93%.

Bock, E. H.↗
NASA NTRS1982

The swing to concentrator arrays

Objectives and progress in both low concentration ratio (6 to 10) and high concentration ratio ( 100) array developments are summarized. Problems encountered include: thermal control, maldistribution of concentrated sunlight, current busing, and optical surface degradation. The potential advantages over planar arrays are an order of magnitude reduction in per unit cost of power plus increased immunity to radiation damage.

Miller, J. L.↗
NASA NTRS1998

The Strutjet Rocket Based Combined Cycle Engine

The multi stage chemical rocket has been established over many years as the propulsion System for space transportation vehicles, while, at the same time, there is increasing concern about its continued affordability and rather involved reusability. Two broad approaches to addressing this overall launch cost problem consist in one, the further development of the rocket motor, and two, the use of airbreathing propulsion to the maximum extent possible as a complement to the limited use of a conventional rocket. In both cases, a single-stage-to-orbit (SSTO) vehicle is considered a desirable goal. However, neither the "all-rocket" nor the "all-airbreathing" approach seems realizable and workable in practice without appreciable advances in materials and manufacturing. An affordable system must be reusable with minimal refurbishing on-ground, and large mean time between overhauls, and thus with high margins in design. It has been suggested that one may use different engine cycles, some rocket and others airbreathing, in a combination over a flight trajectory, but this approach does not lead to a converged solution with thrust-to-mass, specific impulse, and other performance and operational characteristics that can be obtained in the different engines. The reason is this type of engine is simply a combination of different engines with no commonality of gas flowpath or components, and therefore tends to have the deficiencies of each of the combined engines. A further development in this approach is a truly combined cycle that incorporates a series of cycles for different modes of propulsion along a flight path with multiple use of a set of components and an essentially single gas flowpath through the engine. This integrated approach is based on realizing the benefits of both a rocket engine and airbreathing engine in various combinations by a systematic functional integration of components in an engine class usually referred to as a rocket-based combined cycle (RBCC) engine. RBCC engines exhibit a high potential for lowering the operating cost of launching payloads into orbit. Two sources of cost reductions can be identified. First, RBCC powered vehicles require only 20% takeoff thrust compared to conventional rockets, thereby lowering the thrust requirements and the replacement cost of the engines. Second, due to the higher structural and thermal margins achievable with RBCC engines coupled with a higher degree of subsystem redundance lower maintenance and operating cost are obtainable.

Siebenhaar, A.↗
NASA NTRS2003

Materials trade study for lunar/gateway missions

The National Aeronautics and Space Administration (NASA) administrator has identified protection from radiation hazards as one of the two biggest problems of the agency with respect to human deep space missions. The intensity and strength of cosmic radiation in deep space makes this a 'must solve' problem for space missions. The Moon and two Earth-Moon Lagrange points near Moon are being proposed as hubs for deep space missions. The focus of this study is to identify approaches to protecting astronauts and habitats from adverse effects from space radiation both for single missions and multiple missions for career astronauts to these destinations. As the great cost of added radiation shielding is a potential limiting factor in deep space missions, reduction of mass, without compromising safety, is of paramount importance. The choice of material and selection of the crew profile play major roles in design and mission operations. Material trade studies in shield design over multi-segmented missions involving multiple work and living areas in the transport and duty phase of space mission's to two Earth-Moon co-linear Lagrange points (L1) between Earth and the Moon and (L2) on back side of the moon as seen from Earth, and to the Moon have been studied. It is found that, for single missions, current state-of-the-art knowledge of material provides adequate shielding. On the other hand, the choice of shield material is absolutely critical for career astronauts and revolutionary materials need to be developed for these missions. This study also provides a guide to the effectiveness of multifunctional materials in preparation for more detailed geometry studies in progress. c2003 COSPAR. Published by Elsevier Ltd. All rights reserved.

NASA Discipline Radiation Health↗
NASA NTRS1977

Analytical investigation of thermal barrier coatings for advanced power generation combustion turbines

An analytical evaluation was conducted to determine quantitatively the improvement potential in cycle efficiency and cost of electricity made possible by the introduction of thermal barrier coatings to power generation combustion turbine systems. The thermal barrier system, a metallic bond coat and yttria stabilized zirconia outer layer applied by plasma spray techniques, acts as a heat insulator to provide substantial metal temperature reductions below that of the exposed thermal barrier surface. The study results show the thermal barrier to be a potentially attractive means for improving performance and reducing cost of electricity for the simple, recuperated, and combined cycles evaluated.

Amos, D. J.↗
NASA NTRS1994

Shared mission operations concept

Historically, new JPL flight projects have developed a Mission Operations System (MOS) as unique as their spacecraft, and have utilized a mission-dedicated staff to monitor and control the spacecraft through the MOS. NASA budgetary pressures to reduce mission operations costs have led to the development and reliance on multimission ground system capabilities. The use of these multimission capabilities has not eliminated an ongoing requirement for a nucleus of personnel familiar with a given spacecraft and its mission to perform mission-dedicated operations. The high cost of skilled personnel required to support projects with diverse mission objectives has the potential for significant reduction through shared mission operations among mission-compatible projects. Shared mission operations are feasible if: (1) the missions do not conflict with one another in terms of peak activity periods, (2) a unique MOS is not required, and (3) there is sufficient similarity in the mission profiles so that greatly different skills would not be required to support each mission. This paper will further develop this shared mission operations concept. We will illustrate how a Discovery-class mission would enter a 'partner' relationship with the Voyager Project, and can minimize MOS development and operations costs by early and careful consideration of mission operations requirements.

Spradlin, Gary L.↗
NASA NTRS1998

Continued Development and Application of Circulation Control Pneumatic Technology to Advanced Transport Aircraft

Personnel of the Georgia Tech Research Institute (GTRI) Aerospace and Transportation Lab have completed a four-year grant program to develop and evaluate the pneumatic aerodynamic technology known as Circulation Control (CC) or Circulation Control Wing (CCW) for advanced transport aircraft. This pneumatic technology, which employs low-level blowing from tangential slots over round or near-round trailing edges of airfoils, greatly augments the circulation around a lifting or control surface and thus enhances the aerodynamic forces and moments generated by that surface. Two-dimensional force augmentations as high as 80 times the input blowing momentum coefficient have been recorded experimentally for these blown devices, thus providing returns of 8000% on the jet momentum expended. A further benefit is the absence of moving parts such as mechanical flaps, slats, spoilers, ailerons, elevators and rudders from these pneumatic surfaces, or the use of only very small, simple, blown aerodynamic surfaces on synergistic designs which integrate the lift, drag and control surfaces. The application of these devices to advanced aircraft can offer significant benefits in their performance, efficiency, simplicity, reliability, economic cost of operation, noise reduction, and safety of flight. To further develop and evaluate this potential, this research effort was conducted by GTRI under grant for the NASA Langley Research Center, Applied Aerodynamics Division, Subsonic Aerodynamics Branch, between June 14, 1993 and May 31, 1997.

Englar, Robert J.↗
NASA NTRS1998

Benefits of Government Incentives for Reusable Launch Vehicle Development

Many exciting new opportunities in space, both government missions and business ventures, could be realized by a reduction in launch prices. Reusable launch vehicle (RLV) designs have the potential to lower launch costs dramatically from those of today's expendable and partially-expendable vehicles. Unfortunately, governments must budget to support existing launch capability, and so lack the resources necessary to completely fund development of new reusable systems. In addition, the new commercial space markets are too immature and uncertain to motivate the launch industry to undertake a project of this magnitude and risk. Low-cost launch vehicles will not be developed without a mature market to service; however, launch prices must be reduced in order for a commercial launch market to mature. This paper estimates and discusses the various benefits that may be reaped from government incentives for a commercial reusable launch vehicle program.

Shaw, Eric J.↗
NASA NTRS1988

Dragging down fuel costs

It has been suggested that modest reductions in friction drag could save U.S. airlines $200-500 million a year. Potentially significant fuel savings are to be expected from laminar flow control (LFC) with suction surfaces on a CTOL subsonic transport; fuel savings from 25 to 40 percent are possible, depending on stage length. NASA has developed advanced computational design tools and methodology, subsonic and transonic NLF (natural laminar flow) and LFC airfoils, practical laminar wing construction techniques, and practical leading-edge treatments applicable to civil and military transports. It is concluded that skin-friction and induced drag approaches can combine to make a 50 percent reduction a reality for commercial and military aircraft of the future.

Hefner, Jerry N.↗
NASA NTRS2004

Systems Engineering Techniques for ALS Decision Making

The Advanced Life Support (ALS) Metric is the predominant tool for predicting the cost of ALS systems. Metric goals for the ALS Program are daunting, requiring a threefold increase in the ALS Metric by 2010. Confounding the problem, the rate new ALS technologies reach the maturity required for consideration in the ALS Metric and the rate at which new configurations are developed is slow, limiting the search space and potentially giving the perspective of a ALS technology, the ALS Metric may remain elusive. This paper is a sequel to a paper published in the proceedings of the 2003 ICES conference entitled, "Managing to the metric: an approach to optimizing life support costs." The conclusions of that paper state that the largest contributors to the ALS Metric should be targeted by ALS researchers and management for maximum metric reductions. Certainly, these areas potentially offer large potential benefits to future ALS missions; however, the ALS Metric is not the only decision-making tool available to the community. To facilitate decision-making within the ALS community a combination of metrics should be utilized, such as the Equivalent System Mass (ESM)-based ALS metric, but also those available through techniques such as life cycle costing and faithful consideration of the sensitivity of the assumed models and data. Often a lack of data is cited as the reason why these techniques are not considered for utilization. An existing database development effort within the ALS community, known as OPIS, may provide the opportunity to collect the necessary information to enable the proposed systems analyses. A review of these additional analysis techniques is provided, focusing on the data necessary to enable these. The discussion is concluded by proposing how the data may be utilized by analysts in the future.

Rodriquez, Luis F.↗