SEARCH · Engineering Papers

Results for “process design tool”

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 1,297 records · Page 72

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Markov Decision Processes for Intelligent, Risk-Informed Asset-Management Decision-Making

Advanced nuclear reactors are a promising option for aiding the world in achieving its net-zero carbon emission goals, however, there are significant challenges to attaining and maintaining economic competitiveness with other sources of electricity. To improve the economic competitiveness of advanced reactor designs, a project was initiated to explore the use of Markov Decision Processes (MDPs) to guide asset-management decision-making during advanced reactor operation. MDPs are a powerful tool for optimizing decision-making in complex environments and their application to advanced reactors can aid in planning maintenance and repair activities to minimize downtime and maximize generation. The described approach expands on previous work regarding the use of MDPs for operational decision-making through the direct incorporation of real-time plant information. The integral MDP analysis includes information from online component diagnostic tools and the plant’s real-time generation risk assessment (GRA) and probabilistic risk assessment (PRA), which evaluate plant risk from both an economic and safety perspective. The result is an asset-management optimization framework that is based on real-time data regarding plant component status and the current best-estimate of plant risk. The paper presents an overview of the theoretical framework to incorporate the different information pathways into an integral MDP analysis, along with example analyses.

Grabaskas, David↗

NASA NTRS1972

Development of termination and utilization concepts for flat conductor cables. Volume 3: Cost study comparison, flat versus round conductor cable

A cost study comparing flat conductor cable (FCC) with small-gage wire (SGW) and conventional round conductor cable (RCC) is presented. This study was based on a vehicle wiring system consisting of 110,000 ft of conventional RCC equally divided between AWG sizes 20,22, and 24 using MIL-W-81044-type wire and MIL-C-26500 circular connectors. Basic cost data were developed on a similar-sized commercial jet airplane wiring system on a previous company R&D program in which advanced wiring techniques were carried through equivalent installations on an airplane mockup; and on data developed on typical average bundles during this program. Various cost elements included were engineering labor, operations (manufacturing) labor, material costs, and cost impact on payload. Engineering labor includes design, wiring system integration, wiring diagrams and cable assembly drawings, wire installations, and other related supporting functions such as the electronic data processing for the wiring. Operations labor includes mockup, tooling and production planning, fabrication, assembly, installation, and quality control cost impact on payload is the conversion of wiring system weight variations through use of different wiring concepts to program payload benefits in terms of dollars.

Source record↗

NASA NTRS1977

Research directed toward improved echelles for the ultraviolet

Low frequency gratings obtainable with present technology, can meet the grating-efficiency design goals for potential space telescope spectrographs. Gratings made with changes in the three specific parameters: the ruling tool profile, the coating material, and the lubricants used during the ruling process were compared. A series of coatings and test gratings were fabricated and were examined for surface smoothness with a Nomarski differential interference microscope and an electron microsocope. Photomicrographs were obtained to show the difference in smoothness of the various coatings and rulings. Efficiency measurements were made for those test rulings that showed good groove characteristics: smoothness, proper ruling depth, and absence of defects (e.g., streaks, feathered edges and rough sides). Higher grating efficiency should be correlated with the degree of smoothness of both the coating and the grating groove.

Source record↗

NASA NTRS1978

Key issues in application of composites to transport aircraft

The application of composite materials to transport aircraft was identified and reviewed including the major contributing disciplines of design, manufacturing, and processing. Factors considered include: crashworthiness considerations (structural integrity, postcrash fires, and structural fusing), electrical/avionics subsystems integration, lightning, and P-static protection design; manufacturing development, evaluation, selection, and refining of tooling and curing procedures; and major joint design considerations. Development of the DC-10 rudder, DC-10 vertical stabilizer, and the DC-9 wing study project was reviewed. The Federal Aviation Administration interface and the effect on component design of compliance with Federal Aviation Regulation 25 Composite Guidelines are discussed.

Stone, M.↗

NASA NTRS1978

NASTRAN analysis of Tokamak vacuum vessel using interactive graphics

Isoparametric quadrilateral and triangular elements were used to represent the vacuum vessel shell structure. For toroidally symmetric loadings, MPCs were employed across model boundaries and rigid format 24 was invoked. Nonsymmetric loadings required the use of the cyclic symmetry analysis available with rigid format 49. NASTRAN served as an important analysis tool in the Tokamak design effort by providing a reliable means for assessing structural integrity. Interactive graphics were employed in the finite element model generation and in the post-processing of results. It was felt that model generation and checkout with interactive graphics reduced the modelling effort and debugging man-hours significantly.

Miller, A.↗

NASA NTRS1984

Improved techniques of parallel gap welding and monitoring

Welding programs which show that parallel gas welding is a reliable process are discussed. When monitoring controls and nondestructive tests are incorporated into the process, parallel gap welding becomes more reliable and cost effective. The panel fabrication techniques and the HAC thermal cycling test indicate reliable product integrity. The design and building of automated tooling and fixturing for welding are discussed.

Mardesich, N.↗

NASA NTRS1987

Artificial Intelligence (AI), Operations Research (OR), and Decision Support Systems (DSS): A conceptual framework

In recent years there has been increasing interest in applying the computer based problem solving techniques of Artificial Intelligence (AI), Operations Research (OR), and Decision Support Systems (DSS) to analyze extremely complex problems. A conceptual framework is developed for successfully integrating these three techniques. First, the fields of AI, OR, and DSS are defined and the relationships among the three fields are explored. Next, a comprehensive adaptive design methodology for AI and OR modeling within the context of a DSS is described. These observations are made: (1) the solution of extremely complex knowledge problems with ill-defined, changing requirements can benefit greatly from the use of the adaptive design process, (2) the field of DSS provides the focus on the decision making process essential for tailoring solutions to these complex problems, (3) the characteristics of AI, OR, and DSS tools appears to be converging rapidly, and (4) there is a growing need for an interdisciplinary AI/OR/DSS education.

Parnell, Gregory S.↗

NASA NTRS1990

ATC automation concepts

Information on the design of human-centered tools for terminal area air traffic control (ATC) is given in viewgraph form. Information is given on payoffs and products, guidelines, ATC as a team process, automation tools for ATF, and the traffic management advisor.

Erzberger, Heinz↗

NASA NTRS1992

The effect of material heterogeneity in curved composite beams for use in aircraft structures

A design tool is presented for predicting the effect of material heterogeneity on the performance of curved composite beams for use in aircraft fuselage structures. Material heterogeneity can be induced during processes such as sheet forming and stretch forming of thermoplastic composites. This heterogeneity can be introduced in the form of fiber realignment and spreading during the manufacturing process causing a gradient in material properties in both the radial and tangential directions. The analysis procedure uses a separate two-dimensional elasticity solution for the stresses in the flanges and web sections of the beam. The separate solutions are coupled by requiring the forces and displacements match at the section boundaries. Analysis is performed for curved beams loaded in pure bending and uniform pressure. The beams can be of any general cross-section such as a hat, T-, I-, or J-beam. Preliminary results show that geometry of the beam dictates the effect of heterogeneity on performance. Heterogeneity plays a much larger role in beams with a small average radius to depth ratio, R/t, where R is the average radius of the beam and t is the difference between the inside and outside radius. Results of the analysis are in the form of stresses and displacements, and they are compared to both mechanics of materials and numerical solutions obtained using finite element analysis.

Otoole, Brendan J.↗

NASA NTRS2014

Coupled Solid Rocket Motor Ballistics and Trajectory Modeling for Higher Fidelity Launch Vehicle Design

Multi-stage launch vehicles with solid rocket motors (SRMs) face design optimization challenges, especially when the mission scope changes frequently. Significant performance benefits can be realized if the solid rocket motors are optimized to the changing requirements. While SRMs represent a fixed performance at launch, rapid design iterations enable flexibility at design time, yielding significant performance gains. The streamlining and integration of SRM design and analysis can be achieved with improved analysis tools. While powerful and versatile, the Solid Performance Program (SPP) is not conducive to rapid design iteration. Performing a design iteration with SPP and a trajectory solver is a labor intensive process. To enable a better workflow, SPP, the Program to Optimize Simulated Trajectories (POST), and the interfaces between them have been improved and automated, and a graphical user interface (GUI) has been developed. The GUI enables real-time visual feedback of grain and nozzle design inputs, enforces parameter dependencies, removes redundancies, and simplifies manipulation of SPP and POST's numerous options. Automating the analysis also simplifies batch analyses and trade studies. Finally, the GUI provides post-processing, visualization, and comparison of results. Wrapping legacy high-fidelity analysis codes with modern software provides the improved interface necessary to enable rapid coupled SRM ballistics and vehicle trajectory analysis. Low cost trade studies demonstrate the sensitivities of flight performance metrics to propulsion characteristics. Incorporating high fidelity analysis from SPP into vehicle design reduces performance margins and improves reliability. By flying an SRM designed with the same assumptions as the rest of the vehicle, accurate comparisons can be made between competing architectures. In summary, this flexible workflow is a critical component to designing a versatile launch vehicle model that can accommodate a volatile mission scope.

Ables, Brett↗

NASA NTRS2016

Systems Engineering Awareness

The presentation will provide an overview of the fundamentals and principles of Systems Engineering (SE). This includes understanding the processes that are used to assist the engineer in a successful design, build and implementation of solutions. The context of this presentation will be to describe the involvement of SE throughout the life-cycle of a project from cradle to grave. Due to the ever growing number of complex technical problems facing our world, a Systems Engineering approach is desirable for many reasons. The interdisciplinary technical structure of current systems, technical processes representing System Design, Technical Management and Product Realization are instrumental in the development and integration of new technologies into mainstream applications. This tutorial will demonstrate the application of SE tools to these types of problems..

technical management↗

NASA NTRS2019

Inserting New Technologies into Human-Computer Interfaces for Future Lunar and Mars Missions

Plans call for human cislunar operations and lunar surface access, to prepare for eventual Mars missions. NASA will also develop new opportunities in lunar orbit that provide the foundation and act as a gateway for human exploration deeper into the solar system. Current human spaceflight is complex and requires as many as fifty people to support the International Space Station (ISS) Mission Control Center (MCC) in Houston, Texas. These flight controllers in the front and back rooms of the MCC, serve as an extra pair of eyes overseeing the numerous station systems. Deep space missions - to the moon, Mars, and beyond - will be more complex and place challenging mission constraints on the crew. As the round-trip communication delays increase in deep space exploration, more on-board systems autonomy and functionality will be needed to maintain and control the vehicle. These mission constraints will change the Earth-based ground control approach and will demand efficient and effective human-computer interfaces (HCI) to control a highly complex vehicle or habitat system. All of this necessitates a different approach to designing and developing spacecraft and habitats. In the beginning of new human spaceflight programs, focus is typically on launch vehicle and uncrewed spacecraft design and development. The reasoning behind this focus to enable flight testing of an integrated launch vehicle and spacecraft system to ensure it will be safe enough to allow humans on board. This is an essential process for new spacecraft, however, the practical effect is a lack of funding for the spacecraft’s human interfaces development. It can be many years before the human interface development begins, putting it late in the spacecraft lifecycle, when almost all other spacecraft systems and subsystems are already in place. This forces the usage of existing and proven technologies for the HCI interfaces. We posit that putting the human first in a spacecraft design process will yield a more effective spacecraft for exploration and long duration missions. NASA Human Research Program (HRP) has identified inadequate HCI as a risk for future missions. New tools and procedures to aid the crew in operating a complex spacecraft will be required. This paper discusses ongoing activities in the development of the next generation HCI components and systems, and a new approach toward human interfaces for spacecraft.

Salazar, George A.↗

DOE OSTI2020

NREL's Capabilities in Organism Development and Fermentation Sciences Research and Development (R&D)

NREL is developing robust microbial strains and scalable fermentation technologies for converting biomass sugars to fuels and biochemicals, and one-carbon (C1) gaseous substrates (e.g., CO2, CO, CH4) to high-value products. Core capabilities include: (1) Fermentation optimization of aerobic, microaerophilic, and anaerobic cultivation processes of gas and traditional liquid fermentation R&D; (2) Gas mass transfer R&D and CFD modeling for improved reactor design and gas mixing (3) Metabolic engineering in CRISPR editing tools to improve titer, rates, and yields; (4) Probing and optimizing carbon, redox, and energy flux using transcriptomics and fluxomic techniques; and (5) Consolidated bioprocessing (CBP) using cellulose and hemicellulose directly to minimize pretreatment.

BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS,SYNTHETIC ↗

DOE OSTI2020

Accounting for erroneous model structures in biokinetic process models

In engineering practice, model-based design requires not only a good process-based model, but also a good description of stochastic disturbances and measurement errors to learn credible parameter values from observations. However, typical methods use Gaussian error models, which often cannot describe the complex temporal patterns of residuals. Consequently, this results in overconfidence in the identified parameters and, in turn, optimistic reactor designs. Here, we assess the strengths and weaknesses of a method to statistically describe these patterns with autocorrelated error models. This method produces increased widths of the credible prediction intervals following the inclusion of the bias term, in turn leading to more conservative design choices. However, we also show that the augmented error model is not a universal tool, as its application cannot guarantee the desired reliability of the resulting wastewater reactor design.

42 ENGINEERING↗

NASA NTRS2015

Addressing Unison and Uniqueness of Reliability and Safety for Better Integration

For a long time, both in theory and in practice, safety and reliability have not been clearly differentiated, which leads to confusion, inefficiency, and sometime counter-productive practices in executing each of these two disciplines. It is imperative to address the uniqueness and the unison of these two disciplines to help both disciplines become more effective and to promote a better integration of the two for enhancing safety and reliability in our products as an overall objective. There are two purposes of this paper. First, it will investigate the uniqueness and unison of each discipline and discuss the interrelationship between the two for awareness and clarification. Second, after clearly understanding the unique roles and interrelationship between the two in a product design and development life cycle, we offer suggestions to enhance the disciplines with distinguished and focused roles, to better integrate the two, and to improve unique sets of skills and tools of reliability and safety processes. From the uniqueness aspect, the paper identifies and discusses the respective uniqueness of reliability and safety from their roles, accountability, nature of requirements, technical scopes, detailed technical approaches, and analysis boundaries. It is misleading to equate unreliable to unsafe, since a safety hazard may or may not be related to the component, sub-system, or system functions, which are primarily what reliability addresses. Similarly, failing-to-function may or may not lead to hazard events. Examples will be given in the paper from aerospace, defense, and consumer products to illustrate the uniqueness and differences between reliability and safety. From the unison aspect, the paper discusses what the commonalities between reliability and safety are, and how these two disciplines are linked, integrated, and supplemented with each other to accomplish the customer requirements and product goals. In addition to understanding the uniqueness in reliability and safety, a better understanding of unison and commonalities will further help in understanding the interaction between reliability and safety. This paper discusses the unison and uniqueness of reliability and safety. It presents some suggestions for better integration of the two disciplines in terms of technical approaches, tools, techniques, and skills to enhance the role of reliability and safety in supporting a product design and development life cycle. The paper also discusses eliminating the redundant effort and minimizing the overlap of reliability and safety analyses for an efficient implementation of the two disciplines.

Huang, Zhaofeng↗

DOE OSTI2022

Integrated Computational Materials and Mechanical Modeling for Additive Manufacturing of Alloys with Graded Structure Used in Fossil Fuel Power Plants

Wire-arc additive manufacturing (WAAM) has demonstrated its unique capability of producing large-size alloy components with a significantly reduced fabrication time and enhanced geometry design freedom. In this project, the team has developed an ICME (Integrated Computational Materials Engineering) modeling framework, which supports the WAAM of the AUSC (Advanced Ultra-Supercritical) power plant components. The manufacturing design has been applied to Inconel 740H, steel P91, as well as the dissimilar alloy components between steel P91 and Inconel 740H. The ICME model framework is developed by considering two types of modeling. First, mechanistic modeling has been applied to control the printing quality and understand the sequence of the dissimilar printing of the wall structure. The following models have been included in the developed ICME framework: finite element thermal model, grain structure model, residual stress simulation, crystal plasticity model, CALPHAD-based precipitation kinetic model, phase stability prediction, thermal expansion predictive model, and heuristic creep model. Secondary, a physics-based machine learning model has also been developed based on the ICME model structure. The machine learning model development is based on the ICME model prediction with calibration of the experiments. In addition, the WAAM has been utilized as a high-throughput experimental tool rapidly generating a gradient of alloy composition to facilitate experimental database generation for process-structure-property relationships. Such a database directly supported the ICME-enhanced machine learning, which further assisted in intermediate composition block design between P91 and 740H. A high-throughput screening study of the oxidation resistance has been performed based on such high-throughput experimentation. Based on the computational design, several dissimilar alloy manufacturing with post-heat treatment have been performed with a comprehensive evaluation of mechanical performance, including hardness mapping, yield strength, creep resistance. In this project, the single component of P91 and 740H processed by WAAM after heat treatment designed by ICME has demonstrated higher performance in yield strength and creep resistance than the wrought materials. The P91 sample prepared by WAAM with ICME-designed heat treatment performs better than P92 in creep resistance. The designed graded alloy printing with intermediate block shows a promising performance that exceeds the traditional welding. Moreover, the current research indicates the high need for location-specific design analysis with uncertainty quantification, an important topic that deserves more dedicated research. The achievement of this project demonstrated the promising future of WAAM in structural alloy manufacturing for energy power plant development. Successful printing requires synergetic efforts made by manufacturing, mechanical, and materials sciences.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

MaterialsMap: A CALPHAD-based tool to design composition pathways through feasibility map for desired dissimilar materials, demonstrated with resistance spot welding joining of Ag-Al-Cu

Assembly of dissimilar metals can be achieved by different methods, for example, casting, welding, and additive manufacturing (AM). However, undesired phases formed in liquid-phase assembling processes due to solute segregation during solidification diminish mechanical and other properties of the processed parts. In the present work, an open-source software named MaterialsMap, has been developed based on the CALculation of Phase Diagrams (CALPHAD) approach. The primary objective of MaterialsMap is to facilitate the design of an optimal composition pathway for assembling dissimilar alloys with liquid-phases based on the formation of desired and undesired phases along the pathway. In MaterialsMap, equilibrium thermodynamic calculations are used to predict equilibrium phases formed at slow cooling rate, while Scheil-Gulliver simulations are employed to predict non-equilibrium phases formed during rapid cooling. Additionally, by combining these two simulations, MaterialsMap offers a thorough guide for understanding phase formation in various manufacturing processes, assisting users in making informed decisions during material selection and production. As a demonstration of this approach, a compositional pathway was designed from pure Al to pure Cu through Ag using MaterialsMap. The design was experimentally verified using resistance spot welding (RSW).

36 MATERIALS SCIENCE↗

DOE OSTI2020

Application of an Embedded Fracture and Borehole Modeling Approach to the Understanding of EGS Collab Experiment 1

EGS Collab is a series of meso-scale experiments and associated numerical simulation activities being funded by the United States Department of Energy, Geothermal Technologies Office (GTO) to investigate enhanced geothermal system processes under in-situ stress and slightly elevated temperature conditions. This project is designed to provide scientists and engineers with immediate access to impermeable rock at scales larger than possible in the laboratory, but generally smaller than those for commercial production. Immediate access to rock is provided via the existing drifts of the former Homestake Gold Mine, now operated as the Sanford Underground Research Facility in Lead, South Dakota. The objectives of the EGS Collab project are to develop well controlled fracture networks between injector and producer boreholes using normal and shear stimulation for permeability enhancement. The first experimental site was located off the West Access drift on the 4850 Level (4850 feet below ground surface) in phyllite of the Precambrian Poorman formation, and involved the creation of a fracture network comprising a combination of hydraulic and natural fractures. A second experimental site is now being considered near the battery alcove on the 4100 Level in amphibolite and rhyolite of the Yates Unit. Data generated during these experiments will be compared against predictions of a suite of computer codes specifically designed to solve problems involving coupled thermal, hydrological, geomechanical, and geochemical processes. Comparisons between experimental and numerical simulation results will provide code developers with direction for improvements and verification of process models, build confidence in the suite of available numerical tools, and ultimately identify critical future development needs for the geothermal modeling community. Moreover, conducting thorough comparisons of models, modelling approaches, measurement approaches and measured data, via the EGS Collab project, will serve to identify techniques that are most likely to succeed at the Frontier Observatory for Research in Geothermal Energy (FORGE), the GTO’s flagship EGS research effort. Experiment 1 has comprised a series of successful tests, including a long-term chilled-water circulation test, but the testbed has two atypical EGS elements. Active ventilation in the adjacent drift over a 50-year period cooled the testbed rock mass and hydraulic fracturing intersected monitoring boreholes making them conduits for fluid flow. Numerical simulations executed in support of the design of the EGS Collab Experiment 1, computed a radial temperature distribution and stress gradient orthogonal to the drift axis, resulting in the forecast of an oblong hydraulic fracture geometry, extended in the direction of the drift from the stimulation borehole. This paper describes the numerical simulation of long-term chilled-water circulation test with an embedded fracture and borehole modeling approach. The principal objective of the simulation work is show agreement between experimental observations in terms of production fluid temperatures, monitoring borehole temperatures, injection and production pressures, and tracer recoveries using a single conceptual model for the fracture network, using characterization and monitoring data generally available for EGS. A secondary objective is to improve the numerical simulation result comparisons with additional data available from the broader monitoring equipment within the testbed versus deeper, hotter, and more remote EGS. One complicating factor for comparisons between the numerical simulation results and experimental observations, is the Joule-Thomson heating associated with large pressure drops across the fracture network.

numerical simulation, embedded fractures and boreh↗