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Integrating Efficiency of Industry Processes and Practices Alongside Technology Effectiveness in Space Transportation Cost Modeling and Analysis

This paper presents past and current work in dealing with indirect industry and NASA costs when providing cost estimation or analysis for NASA projects and programs. Indirect costs, when defined as those costs in a project removed from the actual hardware or software hands-on labor; makes up most of the costs of today's complex large scale NASA space/industry projects. This appears to be the case across phases from research into development into production and into the operation of the system. Space transportation is the case of interest here. Modeling and cost estimation as a process rather than a product will be emphasized. Analysis as a series of belief systems in play among decision makers and decision factors will also be emphasized to provide context.

Zapata, Edgar↗

Spinoff 1996

By their challenging nature, NASA programs are particularly demanding of technological input. Meeting the aeronautical and space goals of the past four decades has necessitated leading edge advancements across a diverse spectrum that embraces virtually every scientific and technological discipline. Technology is simply knowledge and, like other forms of knowledge, it is often broadly applied and transferable. For that reason, the vast storehouse of technology NASA has built is a national resource, a bank of knowledge available for commercial applications and enhancements to the quality of life-"spinoff"-to new products and processes of benefit to the national economy, industrial efficiency and human welfare. Multiple use of technology has never been more important. Budgetary stringency is reducing the amount of government funding available for new research and development, but at the same time intensifying international competition demands increasing technological innovation to strengthen the U.S. posture in the global marketplace. Reuse of technology offers a relatively inexpensive supplementary means of partnering with industry focused on bringing new products and processes to the market. More than a thousand of spinoff products and processes have emerged from reapplication of technology developed for NASA mission programs. Each has Contributed some measure of benefit to the national economy, productivity or lifestyle; some bring only moderate increments of gain, but many generate benefits of significant order with economic values in the millions of dollars. Other technologies with moderate economic return have added measurably to the quality of life of U.S. citizens. Collectively, they represent a substantial dividend on the national investment in aerospace research. By Congressional mandate, it is NASA's responsibility to promote expansion of spinoff in the public interest. Through its Technology Transfer Program, NASA seeks to encourage greater use of its technological resources by providing a link between the technology and those who might be able to put it to advantageous use. The program's aim is to broaden and accelerate the transfer accomplishments and thereby to gain national benefit in terms of new products, services, and new jobs. This publication is an instrument of-and documents the outcome of-that purpose. It is intended to heighten awareness of the technology available for transfer and its potential for public benefit. Spinoff 1996 is organized in three sections: Section 1, summarizes NASA's current mainline programs, whose objectives require development of new technology and therefore replenish and expand the bank of knowledge available for reapplication. Section 2, the focal point of this volume, contains a representative sampling of spinoff products and processes that resulted from secondary application of NASA technology. Section 3, describes the various mechanisms NASA employs to stimulate technology transfer and lists, in an appendix, contact sources for Further information about the Technology Transfer Program.

Haggerty, James J.↗

Spinoff 1977

The National Aeronautics & Space Administration has many missions but they can all be reduced to a common denominator: to explore Earth and its surroundings, conduct aeronautical research, and put the results to work for the benefit of mankind. At times the benefit may be dimly perceived. Take, for instance, last year's monumental triumph of exploration, the landing of robot spacecraft on Mars. How, some ask, does probing a neighbor planet improve the lot of Earth's people? In two ways: scientific gain and technological advancement. Though perhaps little understood, they are concrete benefits, assets as tangible as sunshine, more valuable than gold. Technological advancement, on the other hand, offers equally important but more immediate returns. Technology is science applied. It is the ability of a society to make things that improve the quality of human existence. It is compounded of intellect and skill, which draw upon the scientific base to bring forth new ideas, inventions, materials and processes. It is, in a word, knowledge. It builds like an inverted pyramid, each level broader than the one . before as successive generations contribute to the cumulative lore. Knowledge is readily transferable. If you build a better mousetrap, you may acquire experience in the course of the project that can be applied to a need totally unrelated to mouse-traping. This transfer process has been going on since the dawn of technology. In the last two decades it has accelerated enormously, spurred by the immense flow of aerospace-stimulated technology. There have been literally thousands of spinoffs, new products and processes that owe their origins to aerospace research. Collectively, they add up to significant gain in terms of personal convenience, human welfare, industrial efficiency, and economic value.

Haggerty, James J.↗

Summary of Technical Interchange Meetings (TIMs) Designed to Enable Earth Independent Medical Operations (EIMO)

The Exploration Medical Capability Element (ExMC) in NASA’s Human Research Program hosted a series of TIMs in 2023-2024 designed to stimulate discussion around specific topics with the goal of enabling EIMO. In context of the thematic constituent elements of EIMO, namely pre-mission planning, acute/emergent/prolonged medical decision making, supply/resource management and task load management, subject matter experts from industry, academia and government (NASA and other Agencies) provided valuable and actionable guidance and recommendations. Earth-based medical experts will remain indispensable for pre-mission planning, however, management of acute/emergent medical contingencies will require a gradual transition of medical care and decision making from terrestrial to space-based assets to enable support of astronaut health and performance and reduce overall mission risk. Key to achieving these enhancements is providing an integrated data system platform capable of utilizing multiple data streams in concert with a variety of on-board databases and passive monitoring of video and wearable sensors to enable a multi-modal, agentic AI-based clinical decision support system (CDSS) to support crew medical officer (CMO) medical decision-making. The EIMO series of TIMs (I-V) have proven to be instructive and portend a significant paradigm shift will be necessary to maintain crew health and performance on exploration class missions. Importantly, since the expected paradigm shift will be significantly different from the methods of operation that have been employed for the majority of missions from the inception of human spaceflight to date, any proposed methods must be deployed in the setting of ongoing operations early and be “tested, reviewed and practiced” while reliable back-up is available to facilitate an Enterprise-wide level of comfort and acceptance. Serious constraints on data transmission coupled with a large and expanding universe of on-board medical informatics data streams will necessitate implementation of a CDSS to supplant the current reliance on support provided by ground-based SMEs. Establishment of trust in the system by CMO/crew and the ground-based medical support team will be essential. Co-development of a CDSS with industry partners will assure that state of the art tools can be employed, and industry efficiencies can be leveraged. Training regimens, materials and tools must evolve to be responsive (just-in-time training) and facilitate autonomous execution of procedures. Proficiency metrics should be established and be based on validated competencies or milestones as opposed to a prescribed number of training hours. Training should be prioritized for broad, translatable skills that have universal application across a variety of medical conditions. Repetition was deemed to be the key to achieving proficiency and emphasis should lie in procedural training which is known to extinguish more rapidly than diagnostic skills. Advanced tools, e.g., extended reality, can provide more realistic and effective training. Use of advanced probabilistic risk assessment tools will be essential to optimize the medical system capability while carefully balancing risk relative to mass/power/volume limitations. Importance of factoring use-life of medical supplies and maintaining awareness of redundancy and opportunity to re-purpose under off nominal situations was emphasized. Consideration of adopting optimized performance standards vs. “good-enough” performance thresholds is warranted. The use of legacy systems as opposed to creating new systems may be preferable. Managing task load and associated cognitive load will be essential to maintain operational safety and behavioral health. ExMC aspires to create a shared EIMO paradigm and strategic vision for advancing medical system design through novel technologies, training, protocols, and support capabilities, built upon the spirit of successful strategies and innovations over the past six decades of space medicine operations.

Jay Lemery↗

A 400-kWe high-efficiency steam turbine for industrial cogeneration

An advanced state-of-the-art steam turbine-generator developed to serve as the power conversion subsystem for the Department of Energy's Sandia National Laboratories' Solar Total-Energy Project (STEP) is described. The turbine-generator, which is designed to provide 400-kW of net electrical power, represents the largest turbine-generator built specifically for commercial solar-powered cogeneration. The controls for the turbine-generator incorporate a multiple, partial-arc entry to provide efficient off-design performance, as well as an extraction control scheme to permit extraction flow regulation while maintaining 110-spsig pressure. Normal turbine operation is achieved while synchronized to a local utility and in a stand-alone mode. In both cases, the turbine-generator features automatic load control as well as remote start-up and shutdown capability. Tests totaling 200 hours were conducted to confirm the integrity of the turbine's mechanical structure and control function. Performance tests resulted in a measured inlet throttle flow of 8,450 pounds per hour, which was near design conditions.

Leibowitz, H. M.↗

Efficient GO2/GH2 Injector Design: A NASA, Industry and University Cooperative Effort

Developing new propulsion components in the face of shrinking budgets presents a significant challenge. The technical, schedule and funding issues common to any design/development program are complicated by the ramifications of the continuing decrease in funding for the aerospace industry. As a result, new working arrangements are evolving in the rocket industry. This paper documents a successful NASA, industry, and university cooperative effort to design efficient high performance GO2/GH2 rocket injector elements in the current budget environment. The NASA Reusable Launch Vehicle (RLV) Program initially consisted of three vehicle/engine concepts targeted at achieving single stage to orbit. One of the Rocketdyne propulsion concepts, the RS 2100 engine, used a full-flow staged-combustion cycle. Therefore, the RS 2100 main injector would combust GO2/GH 2 propellants. Early in the design phase, but after budget levels and contractual arrangements had been set the limitations of the current gas/gas injector database were identified. Most of the relevant information was at least twenty years old. Designing high performance injectors to meet the RS 2100 requirements would require the database to be updated and significantly enhanced. However, there was no funding available to address the need for more data. NASA proposed a teaming arrangement to acquire the updated information without additional funds from the RLV Program. A determination of the types and amounts of data needed was made along with test facilities with capabilities to meet the data requirements, budget constraints, and schedule. After several iterations a program was finalized and a team established to satisfy the program goals. The Gas/Gas Injector Technology (GGIT) Program had the overall goal of increasing the ability of the rocket engine community to design efficient high-performance, durable gas/gas injectors relevant to RLV requirements. First, the program would provide Rocketdyne with data on preliminary gas/gas injector designs which would enable discrimination among candidate injector designs. Secondly, the program would enhance the national gas/gas database by obtaining high-quality data that increases the understanding of gas/gas injector physics and is suitable for computational fluid dynamics (CFD) code validation. The third program objective was to validate CFD codes for future gas/gas injector design in the RLV program.

Tucker, P. K.↗

Shared visions: Partnership of Rockwell International and NASA Cost Effectiveness Enhancements (CEE) for the space shuttle system integration program

As a result of limited resources and tight fiscal constraints over the past several years, the defense and aerospace industries have experienced a downturn in business activity. The impact of fewer contracts being awarded has placed a greater emphasis for effectiveness and efficiency on industry contractors. It is clear that a reallocation of resources is required for America to continue to lead the world in space and technology. The key to technological and economic survival is the transforming of existing programs, such as the Space Shuttle Program, into more cost efficient programs so as to divert the savings to other NASA programs. The partnership between Rockwell International and NASA and their joint improvement efforts that resulted in significant streamlining and cost reduction measures to Rockwell International Space System Division's work on the Space Shuttle System Integration Contract is described. This work was a result of an established Cost Effectiveness Enhancement (CEE) Team formed initially in Fiscal Year 1991, and more recently expanded to a larger scale CEE Initiative in 1992. By working closely with the customer in agreeing to contract content, obtaining management endorsement and commitment, and involving the employees in total quality management (TQM) and continuous improvement 'teams,' the initial annual cost reduction target was exceeded significantly. The CEE Initiative helped reduce the cost of the Shuttle Systems Integration contract while establishing a stronger program based upon customer needs, teamwork, quality enhancements, and cost effectiveness. This was accomplished by systematically analyzing, challenging, and changing the established processes, practices, and systems. This examination, in nature, was work intensive due to the depth and breadth of the activity. The CEE Initiative has provided opportunities to make a difference in the way Rockwell and NASA work together - to update the methods and processes of the organizations. The future success of NASA space programs and Rockwell hinges upon the ability to adopt new, more efficient and effective work processes. Efficiency, proficiency, cost effectiveness, and teamwork are a necessity for economic survival. Continuous improvement initiatives like the CEE are, and will continue to be, vehicles by which the road can be traveled with a vision to the future.

Bejmuk, Bohdan I.↗

Combining total energy and energy industrial center concepts to increase utilization efficiency of geothermal energy

Integrating energy production and energy consumption to produce a total energy system within an energy industrial center which would result in more power production from a given energy source and less pollution of the environment is discussed. Strong governmental support would be required for the crash drilling program necessary to implement these concepts. Cooperation among the federal agencies, power producers, and private industry would be essential in avoiding redundant and fruitless projects, and in exploiting most efficiently our geothermal resources.

Bayliss, B. P.↗

From neural-based object recognition toward microelectronic eyes

Engineering neural network systems are best known for their abilities to adapt to the changing characteristics of the surrounding environment by adjusting system parameter values during the learning process. Rapid advances in analog current-mode design techniques have made possible the implementation of major neural network functions in custom VLSI chips. An electrically programmable analog synapse cell with large dynamic range can be realized in a compact silicon area. New designs of the synapse cells, neurons, and analog processor are presented. A synapse cell based on Gilbert multiplier structure can perform the linear multiplication for back-propagation networks. A double differential-pair synapse cell can perform the Gaussian function for radial-basis network. The synapse cells can be biased in the strong inversion region for high-speed operation or biased in the subthreshold region for low-power operation. The voltage gain of the sigmoid-function neurons is externally adjustable which greatly facilitates the search of optimal solutions in certain networks. Various building blocks can be intelligently connected to form useful industrial applications. Efficient data communication is a key system-level design issue for large-scale networks. We also present analog neural processors based on perceptron architecture and Hopfield network for communication applications. Biologically inspired neural networks have played an important role towards the creation of powerful intelligent machines. Accuracy, limitations, and prospects of analog current-mode design of the biologically inspired vision processing chips and cellular neural network chips are key design issues.

Sheu, Bing J.↗

Fluid Physics and Macromolecular Crystal Growth in Microgravity

The first protein crystallization experiment in microgravity was launched in April, 1981 and used Germany's Technologische Experimente unter Schwerelosigkeit (TEXUS 3) sounding rocket. The protein P-galactosidase (molecular weight 465Kda) was chosen as the sample with a liquid-liquid diffusion growth method. A sliding device brought the protein, buffer and salt solution into contact when microgravity was reached. The sounding rocket gave six minutes of microgravity time with a cine camera and schlieren optics used to monitor the experiment, a single growth cell. In microgravity a strictly laminar diffusion process was observed in contrast to the turbulent convection seen on the ground. Several single crystals, approx 100micron in length, were formed in the flight which were of inferior but of comparable visual quality to those grown on the ground over several days. A second experiment using the same protocol but with solutions cooled to -8C (kept liquid with glycerol antifreeze) again showed laminar diffusion. The science of macromolecular structural crystallography involves crystallization of the macromolecule followed by use of the crystal for X-ray diffraction experiments to determine the three dimensional structure of the macromolecule. Neutron protein crystallography is employed for elucidation of H/D exchange and for improved definition of the bound solvent (D20). The structural information enables an understanding of how the molecule functions with important potential for rational drug design, improved efficiency of industrial enzymes and agricultural chemical development. The removal of turbulent convection and sedimentation in microgravity, and the assumption that higher quality crystals will be produced, has given rise to the growing number of crystallization experiments now flown. Many experiments can be flown in a small volume with simple, largely automated, equipment - an ideal combination for a microgravity experiment. The term "protein crystal growth" is often historically used to describe these microgravity experiments. This is somewhat inaccurate as the field involves the study of many varied biological molecules including viruses, proteins, DNA, RNA and complexes of those structures. For this reason we use the term macromolecular crystal growth. In this chapter we review a series of diagnostic microgravity crystal growth experiments carried out principally using the European Space Agency (ESA) Advanced Protein Crystallization Facility (APCF). We also review related research, both experimental and theoretical, on the aspects of microgravity fluid physics that affect microgravity protein crystal growth. Our experiments have revealed some surprises that were not initially expected. We discuss them here in the context of practical lessons learnt and how to maximize the limited microgravity opportunities available.

Helliwell, John R.↗

Pressure Controller

EPIC is Electronic Pressure Indicating Controller produced by North American Manufacturing Company. It is a high-sensitivity device for improving combustion efficiency in industrial furnaces that interprets a signal from a pressure transducer on a furnace and regulates furnace pressure accordingly. A controller can provide savings of from five to 25 percent of an industrial user's annual furnace fuel bill.

Source record↗

Proceedings of the 2010 NASA-Industry Low Pressure Turbine and Power Turbine (LPT/PT) Efficiency Improvement Workshop

This report includes materials from the NASA-Industry Low Pressure Turbine and Power Turbine (LPT/PT) Efficiency Improvement Workshop that took place on August 10 and 11, 2010, at the NASA Glenn Research Center. The materials include all the presentation slides and a workshop summary article that provides background information, describes the workshop motivation, and provides a summary of the open discussions that took place. Participation included specialists from academia, government laboratories, and industry, from the United States and abroad. The workshop was motivated by underperformance of large commercial engines related to lower-than-expected efficiency of the LPT. It focused on addressing the relevant flow physics. Recommendations were made for continued research. The main recommendation was to conduct rotating rig tests accompanied by the study of fundamental mechanism using computational fluid dynamics (CFD) and turbulence and transition model development.

Transition↗

Advanced component technologies for energy-efficient turbofan engines

A cooperative government-industry effort, the Energy Efficient Engine Project, to develop the advanced technology base for future commercial development of a new generation of more fuel conservative turbofan engines for airline use is described. Engine configurations that are dependent upon technology advances in each major engine component are defined and current design and development of the advanced components are included.

Saunders, N. T.↗

National photovoltaic program

Department of Energy budget plans for 1982 are presented including general funding levels and key program achievements. Activities that are cost-shared with industry are summarized and cell efficiency improvements with time and industry accomplishments are discussed.

Prince, M.↗

Automation of Commanding at NASA: Reducing Human Error in Space Flight

Automation has been implemented in many different industries to improve efficiency and reduce human error. Reducing or eliminating the human interaction in tasks has been proven to increase productivity in manufacturing and lessen the risk of mistakes by humans in the airline industry. Human space flight requires the flight controllers to monitor multiple systems and react quickly when failures occur so NASA is interested in implementing techniques that can assist in these tasks. Using automation to control some of these responsibilities could reduce the number of errors the flight controllers encounter due to standard human error characteristics. This paper will investigate the possibility of reducing human error in the critical area of manned space flight at NASA.

Dorn, Sarah J.↗

Space Coatings for Industry

Ball Aerospace developed entirely new space lubrication technologies. A new family of dry lubricants emerged from Apollo, specifically designed for long life in space, together with processes for applying them to spacecraft components in microscopically thin coatings. Lubricants worked successfully on seven Orbiting Solar Observatory flights over the span of a decade and attracted attention to other contractors which became Ball customers. The company has developed several hundred variations of the original OSO technology generally designed to improve the quality and useful life of a wide range of products or improve efficiency of the industrial processes by which such products are manufactured.

Source record↗

Tree-mendous Timber Evaluation

Funded and administered by NASA, the Affiliated Research Center (ARC) program transfers geospatial technologies from the Space Agency and participating universities to commercial companies, non-profit and trade organizations, and tribal governments. The origins of the ARC program date back to 1988, when NASA's Stennis Space Center initiated the Visiting Investigator Program to bring industry closer to spatial information technologies. The success of this trial program led to an expansion into the ARC program, whose goal is to enhance competitiveness of U.S. industries through more efficient use of remote sensing and related technologies. NASA's ARC program served as the foundation for the development of International Hardwood Resources, which then grew into Falcon Informatics with the acquisition of a technology from a European software company and a change of business models. Doylestown, Pennsylvania-based Falcon Informatics is now a world-leading information services company that combines in-depth timber industry experience with state-of-the-art software to serve the needs of national governments, international paper companies, and timber-investment management organizations.

Source record↗

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗