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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

NASA HUNCH Hardware

What is NASA HUNCH? High School Students United with NASA to Create Hardware-HUNCH is an instructional partnership between NASA and educational institutions. This partnership benefits both NASA and students. NASA receives cost-effective hardware and soft goods, while students receive real-world hands-on experiences. The 2014-2015 was the 12th year of the HUNCH Program. NASA Glenn Research Center joined the program that already included the NASA Johnson Space Flight Center, Marshall Space Flight Center, Langley Research Center and Goddard Space Flight Center. The program included 76 schools in 24 states and NASA Glenn worked with the following five schools in the HUNCH Build to Print Hardware Program: Medina Career Center, Medina, OH; Cattaraugus Allegheny-BOCES, Olean, NY; Orleans Niagara-BOCES, Medina, NY; Apollo Career Center, Lima, OH; Romeo Engineering and Tech Center, Washington, MI. The schools built various parts of an International Space Station (ISS) middeck stowage locker and learned about manufacturing process and how best to build these components to NASA specifications. For the 2015-2016 school year the schools will be part of a larger group of schools building flight hardware consisting of 20 ISS middeck stowage lockers for the ISS Program. The HUNCH Program consists of: Build to Print Hardware; Build to Print Soft Goods; Design and Prototyping; Culinary Challenge; Implementation: Web Page and Video Production.

manufacturing↗
NASA NTRS2015

Evolvable Mars Campaign Long Duration Habitation Strategies: Architectural Approaches to Enable Human Exploration Missions

The Evolvable Mars Campaign (EMC) is the current NASA Mars mission planning effort which seeks to establish sustainable, realistic strategies to enable crewed Mars missions in the mid-2030s timeframe. The primary outcome of the Evolvable Mars Campaign is not to produce "The Plan" for sending humans to Mars, but instead its intent is to inform the Human Exploration and Operations Mission Directorate near-term key decisions and investment priorities to prepare for those types of missions. The FY'15 EMC effort focused upon analysis of integrated mission architectures to identify technically appealing transportation strategies, logistics build-up strategies, and vehicle designs for reaching and exploring Mars moons and Mars surface. As part of the development of this campaign, long duration habitats are required which are capable of supporting crew with limited resupply and crew abort during the Mars transit, Mars moons, and Mars surface segments of EMC missions. In particular, the EMC design team sought to design a single, affordable habitation system whose manufactured units could be outfitted uniquely for each of these missions and reused for multiple crewed missions. This habitat system must provide all of the functionality to safely support 4 crew for long durations while meeting mass and volume constraints for each of the mission segments set by the chosen transportation architecture and propulsion technologies. This paper describes several proposed long-duration habitation strategies to enable the Evolvable Mars Campaign through improvements in mass, cost, and reusability, and presents results of analysis to compare the options and identify promising solutions. The concepts investigated include several monolithic concepts: monolithic clean sheet designs, and concepts which leverage the co-manifested payload capability of NASA's Space Launch System (SLS) to deliver habitable elements within the Universal Payload Adaptor between the SLS upper stage and the Orion/Service module on the top of the vehicle. Multiple modular habitat options for Mars surface and in-space missions are also considered with various functionality and volume splits between modules to find the best balance of reducing the single largest mass which must be delivered to a destination and reducing the number of separate elements which must be launched. Analysis results presented for each of these concepts in this paper include mass/volume/power sizing using parametric sizing tools, identification of unique operational constraints, and limited comments on the additional impacts of reusability/dormancy on system design. Finally, recommendations will be made for promising solutions which will be carried forward for consideration in the Evolvable Mars Campaign work.

Simon, Matthew A.↗
NASA NTRS2018

Towards Design Principles for Visual Analytics in Operations Contexts

Operations engineering teams interact with complex data systems to make technical decisions that ensure the operational efficacy of their missions. To support these decision-making tasks, which may require elastic prioritization of goals dependent on changing conditions, custom analytics tools are often developed. We were asked to develop such a tool by a team at the NASA Jet Propulsion Laboratory, where rover telecom operators make decisions based on models predicting how much data rovers can transfer from the surface of Mars. Through research, design, implementation, and informal evaluation of our new tool, we developed principles to inform the design of visual analytics systems in operations contexts. We offer these principles as a step towards understanding the complex task of designing these systems. The principles we present are applicable to designers and developers tasked with building analytics systems in domains that face complex operations challenges such as scheduling, routing, and logistics.

Lombeyda, Santiago↗
NASA NTRSDate not supplied

Backshell Thermal Protection Materials for Additive Manufacturing

Leveraging AM technology focused on the Fused Deposition Modeling (FDM) process could automate the heat shield manufacturing process and allow it to reduce cost and build time and improve the design to 3D print and process TPS materials directly on the structure in monolith segments. Furthermore, AM allows the production of complicated three-dimensional geometry and density gradient layers without custom molds or special tools. NASA invests in additive manufacturing (AM) to enable new mission architectures and design methods; AM is suited for backshell thermal protection materials that require many complex closeouts that lead to integration challenges. Current work will review backshell thermal protection material formulation, development, and characterization.3D printer was used to 3D print arc-jet test coupons. The coupons were tested at the NASA Ames arc jet facility, and the results show promising properties compared with the heritage materials.

Tane Boghozian↗
NASA NTRSDate not supplied

A Nonlinear Schur Complement Solver for CFD-Based Multidisciplinary Models

CFD-based multidisciplinary models are the fundamental building blocks of multidis- ciplinary design optimization frameworks. Linear and nonlinear solutions of these coupled models are difficult, especially when the Jacobian matrices represent a saddle point problem, where a block-diagonal corresponding to a discipline is non-invertible. These scenarios necessitate the use of a coupled solver algorithm such as the Newton’s method instead of the popular block Gauss– Seidel-based methods because of this non-invertible block. To address this challenge, we introduce a nonlinear Schur complement solver suitable for CFD-based multidisciplinary models. The solver leverages the specialized linear and nonlinear solvers of the CFD code, and therefore, does not require the solution of a large coupled linear system as the coupled Newton’s method. Further- more, because the solver primarily uses the specialized linear and nonlinear solvers of the CFD code, it does not suffer from the same robustness limitations as the coupled Newton’s method. In this work, we will implement this solver in NASA’s OpenMDAO framework and demonstrate its effectiveness using a CFD-based aeropropulsive model. The solver will contribute to the develop- ment of aeropropulsive design optimization and CFD-based design optimization methods with the ultimate goal of accelerating the design and integration of advanced propulsion systems.

Nonlinear Solvers↗
NASA NTRS2021

Assessing Ceres’ Past and Current Habitability

Dwarf planet Ceres is a compelling target as an evolved ocean world with, at least, regional brine reservoirs and potentially ongoing geological activity. Situated in the Main Belt of asteroids, Ceres is the most water-rich body in the inner solar system (in relative abundance) and is accessible enough for a sample return with the resources of a typical medium-class (New Frontiers) NASA mission. NASA’s Dawn mission at Ceres revealed the presence of liquid, brine-driven activity, organic matter, and a rich salt chemistry. With this evidence, the overarching goals of the mission concept presented herein are to quantify Ceres’ current habitability potential and origin. A sample return from young evaporite deposits in Occator crater offers greater science return than an in situ exploration mission by enabling high-resolution analysis of (1) organic matter expected from terrestrial and chondritic analogs that are trapped in salt minerals and (2) isotopes of refractory elements for a similar cost and less science risk. The sample return concept would be executed with a single flight system due to Ceres’ relative proximity to Earth and low gravity. Solar electric propulsion was identified as the most cost-effective approach for getting to Ceres and back. De-orbiting, landing, and takeoff are performed with a throttleable monopropellant hydrazine system. The solar arrays are stowed prior to landing and takeoff. Sample acquisition builds on the pneumatic system designed by Honeybee Robotics. The sample return mission concept relies on the availability of key technologies: an enhanced landing vision system leveraging investments from Mars 2020; retractable/redeployable solar arrays, which have been demonstrated on the International Space Station but not at Ceres’ gravity; and an emerging design from upcoming missions for sample transfer from the pneumatic sampling system to the sample return capsule. Return of a sample of mass ~100 g from Ceres, maintained at ≤ -20°C, is without precedent for any currently advocated Ocean World mission, enabling a vast range of experimental techniques back on Earth with sensitivities and accuracies far beyond those feasible with in situ instruments. A sample of this size also enables analyses to benefit from techniques that will become available in the future.

Casillas, Raul Polit↗
NASA NTRS2024

Establishing Standards for Lunar In Situ Resource Utilization Structural Materials

Lunar structures will be exposed to one of the most extreme environments that have ever been considered for human settlements. In situ, regolith-based materials are being proposed for construction on the moon, offering the benefit of reducing the cost of transporting large amounts of materials or prefabricated elements, and relying on the ability to transport mainly the equipment needed to construct landing pads, shelters, blast shields, habitats, roadways, etc. However, the properties of materials that are made, all or in part, from indigenous lunar resources are likely to change based on the make-up of the material, the location where it was taken from, the production processes, and time. No standards or building codes exist for the design and construction of infrastructure on the moon. Engineers will need dependable information about these materials before any design can be completed. Hard-won lessons from centuries of using similar resources on Earth need to be leveraged to develop the best procedures that will be critical for testing such materials for structural applications. Here we discuss the technical challenges of establishing such standards. Using the timely example of a landing pad on the moon, we identify the gaps in both knowledge and testing capabilities that exist today.

Shirley J. Dyke↗
DOE OSTI2019

Plant Water Profiler: A Tool for Understanding Water Use, Cost and Savings Potential for Manufacturing Plants

In the 1746 Poor Richard’s Almanack, Benjamin Franklin published “When the well’s dry, we know the worth of water” (Franklin, 1746); industrial water users have begun to see the truth in these words as they examine the potential and reality of water scarcity becoming a significant business risk. Through the authors’ interactions with manufacturers via the U.S. Department of Energy’s Better Plants program and Strategic Analysis projects, they realized that manufacturing facilities often do not fully understand the risks to the water supply and the consequential risks to their business. The authors’ also noticed that many facilities do not know how their water is used (baselining), how they compare with their peers (benchmarking), the actual cost impacts of water use (true cost of water), and potential areas for water savings. This results in a lack of motivation and ability to identify and implement effective water-efficiency measures.The Plant Water Profiler Tool (PWP) was created to help manufacturing plant management address these issues by identifying and accounting for water use in manufacturing operations, helping determine the true cost of water, and providing some high-level estimates for peer comparison. The PWP uses a water mass balance and common engineering equations to estimate water use by each of the facility’s systems (e.g., differentiating process water use from cooling and restroom water use), even when no submetering data is available. This new tool also helps users identify possible areas for water savings and associated water and energy cost savings, making it a potentially useful resource for corporations conducting water assessments. Additionally, governments and private organizations can use the methodology behind this tool to design a survey to help build a database of industrial water use. This paper and corresponding presentation provide an overview of current industrial water use practices and tools, as well as the value of determining the true cost of water. It also briefly describes the methodology behind the tool, then focuses on its functionality through an industrial case study and lessons learned from implementing the case study.

Armstrong, Kristina O.↗
DOE OSTI2021

GHG policy impacts for Seattle’s buildings: targets, timing, and scope

Many US cities are addressing climate change by setting goals to reduce their greenhouse gas (GHG) emissions by a specified amount within a specified time period. In order to achieve these goals, reducing emissions from existing buildings is crucial. Many cities are passing legislation to target existing buildings through benchmarking, auditing, retuning, or energy or emissions performance standards. As cities design legislation, they must consider the timing of the policies, how to prioritize building types and sizes, and how these design decisions will impact the city’s emissions. This paper addresses these questions for one particular US city: Seattle, Washington. A model of Seattle’s building stock was created with benchmarking and tax assessor data. It was then used to predict GHG emissions reductions due to different policy implementations for existing commercial and multifamily buildings. Key findings are: (1) the proposed emissions policy is expected to reduce cumulative emissions from buildings by 19% between 2020 and 2050; (2) delaying the implementation of the policy by five years could limit savings to 12%; and (3) including smaller buildings in the policy could increase savings to 34%. The lessons learned and how this can be used by other cities are discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Monitoring of Unvented Roofs with Fibrous Insulation, Diffusion Vents, and Interior Vapor Control in a Cold Climate

Unvented roof assemblies have been accepted in North American building codes since 2007; code-compliant construction calls for a minimum thickness of “air-impermeable insulation” (based on climate zone) to avoid cold-weather condensation and moisture risks. This is typically implemented with polyurethane spray foam insulation; however, negatives of this material include high first cost and possible adverse environmental impacts. Implementing unvented roofs in a moisture-safe manner with air-permeable fibrous fill insulations (e.g., fiberglass or cellulose) could potentially reduce the first cost of unvented roof designs, allowing for more widespread use. Building unvented roofs in a cost-effective, airtight, and moisture-safe manner opens up options for high-performance house designers and builders.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1993

PERTS: A Prototyping Environment for Real-Time Systems

PERTS is a prototyping environment for real-time systems. It is being built incrementally and will contain basic building blocks of operating systems for time-critical applications, tools, and performance models for the analysis, evaluation and measurement of real-time systems and a simulation/emulation environment. It is designed to support the use and evaluation of new design approaches, experimentations with alternative system building blocks, and the analysis and performance profiling of prototype real-time systems.

Liu, Jane W. S.↗
NASA NTRS2011

Object-Oriented Multi-Disciplinary Design, Analysis, and Optimization Tool

An Object-Oriented Optimization (O3) tool was developed that leverages existing tools and practices, and allows the easy integration and adoption of new state-of-the-art software. At the heart of the O3 tool is the Central Executive Module (CEM), which can integrate disparate software packages in a cross platform network environment so as to quickly perform optimization and design tasks in a cohesive, streamlined manner. This object-oriented framework can integrate the analysis codes for multiple disciplines instead of relying on one code to perform the analysis for all disciplines. The CEM was written in FORTRAN and the script commands for each performance index were submitted through the use of the FORTRAN Call System command. In this CEM, the user chooses an optimization methodology, defines objective and constraint functions from performance indices, and provides starting and side constraints for continuous as well as discrete design variables. The structural analysis modules such as computations of the structural weight, stress, deflection, buckling, and flutter and divergence speeds have been developed and incorporated into the O3 tool to build an object-oriented Multidisciplinary Design, Analysis, and Optimization (MDAO) tool.

Pak, Chan-gi↗
DOE OSTI2020

Dynamic System Scaling Applied to Zr-4 Cladding under RIA Conditions

The research and development lifecycle for new fuel designs currently has an ideal 20-25 year timeline. Efforts are currrently underway to accelerate fuel design and development using high performance fuel modeling codes and reduced scale experiments with new instrumentation techniques. However current tools available require a full scale prototype to be designed and tested for fuel qualification. The thermal-hydraulics community has leveraged scaling methodologies to use reduced scale integral effect test facilities (Westinghouse AP600/1000, NuScale Power Module) in lieu of building full scale prototypes for reactor design certification. Dynamic System Scaling (DSS) is a recent development to scaling methodologies that enable the tracking and quantification of dynamic scaling distortions experienced throughout a transient. Recent TREAT experiments performed reactivity initiated accident (RIA) pulses on UO2 fuel rodlets in Zr-4 cladding and were accompanied by BISON predictions for the cladding temperature. DSS is applied to pyrometer data of outer cladding temperatures and two BISON predictions after peak cladding temperature has been reached. One BISON case uses a constant gap conductance value between the fuel and cladding and the other using a conventional gap conductance model. Results from the DSS analysis show that there is good agreement between both BISON predictions and the experimental data and that there is not a significant distortion seen between using either gap conductance model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1999

Launch Vehicle Design Process Description and Training Formulation

A primary NASA priority is to reduce the cost and improve the effectiveness of launching payloads into space. As a consequence, significant improvements are being sought in the effectiveness, cost, and schedule of the launch vehicle design process. In order to provide a basis for understanding and improving the current design process, a model has been developed for this complex, interactive process, as reported in the references. This model requires further expansion in some specific design functions. Also, a training course for less-experienced engineers is needed to provide understanding of the process, to provide guidance for its effective implementation, and to provide a basis for major improvements in launch vehicle design process technology. The objective of this activity is to expand the description of the design process to include all pertinent design functions, and to develop a detailed outline of a training course on the design process for launch vehicles for use in educating engineers whose experience with the process has been minimal. Building on a previously-developed partial design process description, parallel sections have been written for the Avionics Design Function, the Materials Design Function, and the Manufacturing Design Function. Upon inclusion of these results, the total process description will be released as a NASA TP. The design function sections herein include descriptions of the design function responsibilities, interfaces, interactive processes, decisions (gates), and tasks. Associated figures include design function planes, gates, and tasks, along with other pertinent graphics. Also included is an expanded discussion of how the design process is divided, or compartmentalized, into manageable parts to achieve efficient and effective design. A detailed outline for an intensive two-day course on the launch vehicle design process has been developed herein, and is available for further expansion. The course is in an interactive lecture/workshop format to engage the participants in active learning. The course addresses the breadth and depth of the process, requirements, phases, participants, multidisciplinary aspects, tasks, critical elements,as well as providing guidance from previous lessons learned. The participants are led to develop their own understanding of the current process and how it can be improved. Included are course objectives and a session-by-session outline of course content. Also included is an initial identification of visual aid requirements.

Atherton, James↗
NASA NTRS2004

Automated Composites Processing Technology: Film Module

NASA's Marshall Space Flight Center (MSFC) has developed a technology that combines a film/adhesive laydown module with fiber placement technology to enable the processing of composite prepreg tow/tape and films, foils or adhesives on the same placement machine. The development of this technology grew out of NASA's need for lightweight, permeation-resistant cryogenic propellant tanks. Autoclave processing of high performance composites results in thermally-induced stresses due to differences in the coefficients of thermal expansion of the fiber and matrix resin components. These stresses, together with the reduction in temperature due to cryogen storage, tend to initiate microcracking within the composite tank wall. One way in which to mitigate this problem is to introduce a thin, crack-resistant polymer film or foil into the tank wall. Investigation into methods to automate the processing of thin film or foil materials into composites led to the development of this technology. The concept employs an automated film supply and feed module that may be designed to fit existing fiber placement machines, or may be designed as integral equipment to new machines. This patent-pending technology can be designed such that both film and foil materials may be processed simultaneously, leading to a decrease in part build cycle time. The module may be designed having a compaction device independent of the host machine, or may utilize the host machine's compactor. The film module functions are controlled by a dedicated system independent of the fiber placement machine controls. The film, foil, or adhesive is processed via pre-existing placement machine run programs, further reducing operational expense.

Hulcher, A. Bruce↗
NASA NTRS2005

MER : from landing to six wheels on Mars ... twice

Application of the Pathfinder landing system design to enclose the much larger Mars Exploration Rover required a variety of Rover deployments to achieve the surface driving configuration. The project schedule demanded that software design, engineering model test, and flight hardware build to be accomplished in parallel. This challenge was met through (a) bounding unknown environments against which to design and test, (b) early mechanical prototype testing, (c) constraining the scope of on-board autonomy to survival-critical deployments, (d) executing a balance of nominal and off-nominal test cases, (e) developing off-nominal event mitigation techniques before landing, (f) flexible replanning in response to surprises during operations. Here is discussed several specific events encountered during initial MER surface operations.

Mars Exploration Rover (MER)↗
DOE OSTI2020

Design and Implementation of Full-Scale Industrial Control System Test Bed for Assessing Cyber-Security Defenses

In response to the increasing awareness of the Ethernet-based threat surface of industrial control systems (ICS), both the research and commercial communities are responding with ICS-specific security solutions. Unfortunately, many of the properties of ICS environments that contribute to the extent of this threat surface (e.g. age of devices, inability or unwillingness to patch, criticality of the system) similarly prevent the proper testing and evaluation of these security solutions. Production environments are often too fragile to introduce unvetted technology and most organizations lack test environments that are sufficiently consistent with production to yield actionable results. Cost and space requirements prevent the creation of mirrored physical environments leading many to look towards simulation or virtualization. Examples in literature provide various approaches to building ICS test beds, though most of these suffer from a lack of realism due to contrived scenarios, synthetic data and other compromises. In this paper, we provide a design methodology for building highly realistic ICS test beds for validating cybersecurity defenses. We then apply that methodology to the design and building of a specific test bed and describe the results and experimental use cases.

Gillen, Rob↗
DOE OSTI2021

The Design, Construction and Testing of the Straw Tracking Detectors for the E989 Muon g-2 Experiment at Fermilab.

The requirement of science, to stretch the boundaries and our understanding of the standard model,is the driving force for the continuous development of our knowledge of the building blocks of theUniverse. Experiments are designed, built and tested to support the theories of the mathematiciansof the physics community and the theorists help interpret the experimental results, looking foravenues of new physics. However, as is known in both science and human nature, nothing is everperfect - there is always room for improvement.The E989 Muon g-2 Collaboration experiment at Fermi National Accelerator Laboratory (otherwiseknown as Fermilab), aims to quantify the muon anomalous magnetic moment to unprecedentedprecision and looks to increase the accuracy of the measurement by fourfold of the predecessorexperiment - E821 at Brookhaven. The discrepancy between the theoretical prediction of theanomalous magnetic moment of the muon and the experimental results, has given tantalisingindication of new physics, prompting an ”upgrade” for systematic accuracy on the E821.The particular focus of this thesis details the design, construction and quality testing of the strawtracking modules for the E989 experiment. The author was one of the dedicated technicians whobuilt and tested the tracker modules at the University of Liverpool High Energy Physics (HEP)department, she built and quality tested the modules, wrote the procedural document for the buildand subsequently was involved in the Run I startup, shut down and data taking shifts (for Run Iand Run II) which contributed to the recent release of the first unblinded data.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗