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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

Investigation of test methods, material properties and processes for solar cell encapsulants

The goal of the program is to identify, test, evaluate and recommend encapsulation materials and processes for the fabrication of cost-effective and long life solar modules. Of the $18 (1948 $) per square meter allocated for the encapsulation components approximately 50% of the cost ($9/sq m) may be taken by the load bearing component. Due to the proportionally high cost of this element, lower costing materials were investigated. Wood based products were found to be the lowest costing structural materials for module construction, however, they require protection from rainwater and humidity in order to acquire dimensional stability. The cost of a wood product based substrate must, therefore, include raw material costs plus the cost of additional processing to impart hygroscopic inertness. This protection is provided by a two step, or split process in which a flexible laminate containing the cell string is prepared, first in a vacuum process and then adhesively attached with a back cover film to the hardboard in a subsequent step.

Willis, P. B.↗
NASA NTRS1977

A comparison of photointerpretive and digital production methods for four key remote sensing-based information products

This paper evaluates the costs of producing four remote sensing-based information products: timber volume estimate tables, Level II land use/land cover maps, soil maps, and vegetative cover maps. Two production methods for each product are evaluated, one is based on digital processing of satellite data, and the other on conventional photointerpretation of aircraft data. For each product, a comparison is conducted of the two strategies' production costs (including data acquisition, 'ground truthing', interpretation, compilation, and printing charges) and their performance (as measured by accuracy and timeliness). Each of the production methods reviewed has been demonstrated - either operationally or experimentally - and the costs, timeliness and other performance estimates presented are based on observations made in practice. The results show that for these products, satellite-based production results in significant cost and timeliness improvements at the cost of a loss in accuracy.

Eastwood, L. F., Jr.↗
NASA NTRS1993

Low cost manned Mars mission based on indigenous propellant production

The paper describes a low-cost approach to the manned exploration of Mars (which involves an unmanned mission followed two years later by a manned mission) based on near-term technologies and in situ propellant production. Particular attention is given to the basic mission architecture and its major components, including the orbital analysis, the unmanned segment, the Earth Return Vehicle, the aerobrake design, life sciences, guidance, communications, power, propellant production, the surface rovers, and Mars science. Also discussed are the cost per mission over an assumed 8-yr initiative.

Bruckner, A. P.↗
NASA NTRS1992

Project Minerva: A low-cost manned Mars mission based on indigenous propellant production

Project Minerva is a low-cost manned Mars mission designed to deliver a crew of four to the Martian surface, using only two sets of two launches. Key concepts which make this mission realizable are the use of near-term technologies and in-situ propellant production, following the senario originally proposed by R. Zubrin of Martin Marietta. The first set of launches delivers two unmanned payloads into low earth orbit (LEO): one consists of an Earth Return Vehicle (ERV), a propellant production plant, and a set of robotic vehicles, and the second consists of the upper stage/trans-Mars injection (TMI) booster. In LEO, the two payloads are joined and inserted into a Mars transfer orbit. The landing on Mars is performed with the aid of multiple aerobraking maneuvers. On the Martian surface, the propellant production plant uses a Sabatier/electrolysis-type process to combine six tons of hydrogen brought from earth with carbon dioxide from the Martian atmosphere to produce 100 tons of liquid oxygen and methane, which are later used as the propellants for the rover expeditions and the manned return journey of the ERV. Once the in-situ propellant production is completed, approximately two years after the first set of launches, the manned portion of the mission leaves earth. This set of two launches is similar to that of the unmanned vehicles; the two payloads are the Manned Transfer Vehicle (MTV) and the upper stage/TMI booster. The MTV contains the manned rover and the habitat which houses the astronauts enroute to Mars and on the Martian surface. During the 180-day trip to Mars, artificial gravity is created by tethering the MTV to the TMI booster and inducing rotation. Upon arrival the MTV performs aerobraking maneuvers to land near the fully-fueled ERV, which will be used by the crew a year and a half later to return to earth. The mission entails moderate travel times with relatively low-energy conjunction-class trajectories and allows ample time for scientific exploration. This set of missions can be repeated every two years in order to continue exploration at a variety of sites and gradually establish the infrastructure for a permanent base on Mars.

Bruckner, Adam P.↗
NASA NTRS1992

Project Minerva: A low cost manned Mars mission based on indigenous propellant production

Project Minerva is a low-cost manned Mars mission designed to deliver a crew of four to the Martian surface using only two sets of two launches from the Kennedy Space Center. Key concepts which make this mission realizable are the use of near-term technologies and in-situ propellant production, following the scenario originally proposed by R. Zubrin. The first set of launches delivers two unmanned payloads into low Earth orbit (LEO): the first payload consists of an Earth Return Vehicle (ERV), a propellant production plant, and a set of robotic vehicles; the second payload consists of the trans-Mars injection (TMI) upper stage. In LEO, the two payloads are docked and the configuration is injected into a Mars transfer orbit. The landing on Mars is performed with the aid of multiple aerobraking maneuvers. On the Martian surface, the propellant production plant uses a Sabatier/electrolysis type process to combine nine tons of hydrogen with carbon dioxide from the Martian atmosphere to produce over a hundred tons of liquid oxygen and liquid methane, which are later used as the propellants for the rover expeditions and the manned return journey of the ERV. The systems necessary for the flights to and from Mars, as well as those needed for the stay on Mars, are discussed. These systems include the transfer vehicle design, life support, guidance and communications, rovers and telepresence, power generation, and propellant manufacturing. Also included are the orbital mechanics, the scientific goals, and the estimated mission costs.

Beder, David↗
NASA NTRS1997

Managing Technical and Cost Uncertainties During Product Development in a Simulation-Based Design Environment

An approach for objective and quantitative technical and cost risk analysis during product development, which is applicable from the earliest stages, is discussed. The approach is supported by a software tool called the Analytical System for Uncertainty and Risk Estimation (ASURE). Details of ASURE, the underlying concepts and its application history, are provided.

Karandikar, Harsh M.↗
NASA NTRS2002

Predicting Production Costs for Advanced Aerospace Vehicles

For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This paper outlines the development of a process-based cost model in which the physical elements of the vehicle are soared according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this paper is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool.

Bao, Han P.↗
NASA NTRS2002

Process Cost Modeling for Multi-Disciplinary Design Optimization

For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This report outlines the development of a process-based cost model in which the physical elements of the vehicle are costed according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this report is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool. In successive sections, the report addresses the issues of cost modeling as follows. First, an introduction is presented to provide the background for the research work. Next, a quick review of cost estimation techniques is made with the intention to highlight their inappropriateness for what is really needed at the conceptual phase of the design process. The First-Order Process Velocity Cost Model (FOPV) is discussed at length in the next section. This is followed by an application of the FOPV cost model to a generic wing. For designs that have no precedence as far as acquisition costs are concerned, cost data derived from the FOPV cost model may not be accurate enough because of new requirements for shape complexity, material, equipment and precision/tolerance. The concept of Cost Modulus is introduced at this point to compensate for these new burdens on the basic processes. This is treated in section 5. The cost of a design must be conveniently linked to its CAD representation. The interfacing of CAD models and spreadsheets containing the cost equations is the subject of the next section, section 6. The last section of the report is a summary of the progress made so far, and the anticipated research work to be achieved in the future.

Bao, Han P.↗
NASA NTRS1976

Flight service evaluation of an advanced composite empennage component on commercial transport aircraft

The development and flight evaluation of an advanced composite empennage component is presented. The recommended concept for the covers is graphite-epoxy hats bonded to a graphite-epoxy skin. The hat flare-out has been eliminated, instead the hat is continuous into the joint. The recommended concept for the spars is graphite-epoxy caps and a hybrid of Kevlar-49 and graphite-epoxy in the spar web. The spar cap, spar web stiffeners for attaching the ribs, and intermediate stiffeners are planned to be fabricated as a unit. Access hole in the web will be reinforced with a donut type, zero degree graphite-epoxy wound reinforcement. The miniwich design concept in the upper three ribs originally proposed is changed to a graphite-epoxy stiffened solid laminate design concept. The recommended configuration for the lower seven ribs remains as graphite-epoxy caps with aluminum cruciform diagonals. The indicated weight saving for the current advanced composite vertical fin configuration is 20.2% including a 24 lb growth allowance. The project production cost saving is approximately 1% based on a cumulative average of 250 aircraft and including only material, production labor, and quality assurance costs.

Source record↗
NASA NTRS2014

Launch Vehicle Production and Operations Cost Metrics

Traditionally, launch vehicle cost has been evaluated based on $/Kg to orbit. This metric is calculated based on assumptions not typically met by a specific mission. These assumptions include the specified orbit whether Low Earth Orbit (LEO), Geostationary Earth Orbit (GEO), or both. The metric also assumes the payload utilizes the full lift mass of the launch vehicle, which is rarely true even with secondary payloads.1,2,3 Other approaches for cost metrics have been evaluated including unit cost of the launch vehicle and an approach to consider the full program production and operations costs.4 Unit cost considers the variable cost of the vehicle and the definition of variable costs are discussed. The full program production and operation costs include both the variable costs and the manufacturing base. This metric also distinguishes operations costs from production costs, including pre-flight operational testing. Operations costs also consider the costs of flight operations, including control center operation and maintenance. Each of these 3 cost metrics show different sensitivities to various aspects of launch vehicle cost drivers. The comparison of these metrics provides the strengths and weaknesses of each yielding an assessment useful for cost metric selection for launch vehicle programs.

Watson, Michael D.↗
NASA NTRS1980

Cost and price estimate of Brayton and Stirling engines in selected production volumes

The methods used to determine the production costs and required selling price of Brayton and Stirling engines modified for use in solar power conversion units are presented. Each engine part, component and assembly was examined and evaluated to determine the costs of its material and the method of manufacture based on specific annual production volumes. Cost estimates are presented for both the Stirling and Brayton engines in annual production volumes of 1,000, 25,000, 100,000 and 400,000. At annual production volumes above 50,000 units, the costs of both engines are similar, although the Stirling engine costs are somewhat lower. It is concluded that modifications to both the Brayton and Stirling engine designs could reduce the estimated costs.

Fortgang, H. R.↗
NASA NTRS2003

Market Assessment of Forward-Looking Turbulence Sensing Systems

This viewgraph presentation provides a cost benefit analysis of three next-generation forward-looking turbulence sensing systems: X band turbulence radar system for convective turbulence, LIDAR based turbulence systems to sense clear air turbulence and a combined hybrid system. Parameters for the cost benefit analysis were established using a business model which considered injury rates, cost of injuries, indirect costs, market penetration rate estimates and product success characteristics. Topics covered include: study approach, business case equations, data acquisition, benchmark analysis. Data interpretation from the cost benefit analysis is presented. The researchers conclude that the market potential for these products is based primarily on injury cost reduction and that X band radar systems have the greatest chance for commercial success.

Kauffmann, Paul↗
NASA NTRS1983

Benefits and costs of low thrust propulsion systems

The results of costs/benefits analyses of three chemical propulsion systems that are candidates for transferring high density, low volume STS payloads from LEO to GEO are reported. Separate algorithms were developed for benefits and costs of primary propulsion systems (PPS) as functions of the required thrust levels. The life cycle costs of each system were computed based on the developmental, production, and deployment costs. A weighted criteria rating approach was taken for the benefits, with each benefit assigned a value commensurate to its relative worth to the overall system. Support costs were included in the costs modeling. Reference missions from NASA, commercial, and DoD catalog payloads were examined. The program was concluded reliable and flexible for evaluating benefits and costs of launch and orbit transfer for any catalog mission, with the most beneficial PPS being a dedicated low thrust configuration using the RL-10 system.

Robertson, R. I.↗
NASA NTRS2019

In-situ Mechanical Neutron Diffraction Loading Characteristics of GRCop-84 Fabricated by SLM

GRCop-84 is a precipitation strengthened alloy composed of Cu-8Cr-4Nb at % with Cr2Nb precipitates that provide dispersion and precipitation strengthening characteristics and limited solubility in the Cu matrix. The particle role of Cr2Nb(C15Laves) is unusual only contributing 1/3 of strengthening at high temperatures while the matrix provides the remainder. The particles mechanically and thermally stabilize the matrix retaining purity and preventing coarsening and loss of strength. At high temperatures (50-85%TmCu), GRCop-84 provides the best thermal and mechanical properties of available alloys. GRCop-84 is currently in development for reusable launch vehicles including the Space Launch System (SLS) with a focus on fabrication with additive manufacturing (AM) techniques. GRCop-84 is an optimal material for consolidating with AM. The base material is costly, the production times are long, and more geometry control can considerably improve cooling efficiency. Development of AMGR Cop-84 with selective laser melting (SLM) has rapidly progressed due to ease of printing and limited operator adjustment between builds, but the necessary knowledge-base of thermal history and stress state during builds is still under development.

Minneci, R.↗
NASA NTRS2017

Monocrystalline Silicon and the Meta-Shell Approach to Building X-Ray Astronomical Optics

Angular resolution and photon-collecting area are the two most important factors that determine the power of an X-ray astronomical telescope. The grazing incidence nature of X-ray optics means that even a modest photon-collecting area requires an extraordinarily large mirror area. This requirement for a large mirror area is compounded by the fact that X-ray telescopes must be launched into, and operated in, outer space, which means that the mirror must be both lightweight and thin. Meanwhile the production and integration cost of a large mirror area determines the economical feasibility of a telescope. In this paper we report on a technology development program whose objective is to meet this three-fold requirement of making astronomical X-ray optics: (1) angular resolution, (2) photon-collecting area, and (3) production cost. This technology is based on precision polishing of monocrystalline silicon for making a large number of mirror segments and on the meta-shell approach to integrate these mirror segments into a mirror assembly. The meta-shell approach takes advantage of the axial or rotational symmetry of an X-ray telescope to align and bond a large number of small, lightweight mirrors into a large mirror assembly. The most important features of this technology include: (1) potential to achieve the highest possible angular resolution dictated by optical design and diffraction; and (2) capable of implementing every conceivable optical design, such as Wolter-I, Wolter-Schwarzschild, as well as other variations to one or another aspect of a telescope. The simplicity and modular nature of the process makes it highly amenable to mass production, thereby making it possible to produce very large X-ray telescopes in a reasonable amount of time and at a reasonable cost. As of June 2017, the basic validity of this approach has been demonstrated by finite element analysis of its structural, thermal, and gravity release characteristics, and by the fabrication, alignment, bonding, and X-ray testing of mirror modules. Continued work in the coming years will raise the technical readiness of this technology for use by SMEX, MIDEX, Probe, as well as major flagship missions.

Zhang, William W.↗
NASA NTRS1980

Solar total energy-large scale experiment, Shenandoah, Georgia

The design and development of a 7 meter diameter parabolic dish solar collector are discussed. Each of the four main subsystems of the collector: (1) reflector, (2) mount and drives, (3) receiver and (4) the controls, is discussed briefly with the major emphasis on the receiver design. To minimize development risks and production costs, a dish design based on use of stamped aluminum petals (sectors) was chosen. This design is similar to the design of a communication antenna already commercially produced. The reflective surface of the petals has a total reflectance of .86 and a specularity (dispersion) of 8 mrd. This performance is obtained by mechanical polishing and chemical brightening of the petal surface, followed by application of a clear RTV silicone protective coating. Selection of the material and weather proofing coated are discussed. Results from performance tests on an engineering development dish collector are presented and compared with pretest predictions.

Hensley, W. R.↗
NASA NTRS1992

Arrow 227: Air transport system design simulation

The Arrow 227 is a student-designed commercial transport for use in a overnight package delivery network. The major goal of the concept was to provide the delivery service with the greatest potential return on investment. The design objectives of the Arrow 227 were based on three parameters; production cost, payload weight, and aerodynamic efficiency. Low production cost helps to reduce initial investment. Increased payload weight allows for a decrease in flight cycles and, therefore, less fuel consumption than an aircraft carrying less payload weight and requiring more flight cycles. In addition, fewer flight cycles will allow a fleet to last longer. Finally, increased aerodynamic efficiency in the form of high L/D will decrease fuel consumption.

Bontempi, Michael↗