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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Process design tools and techno-economic analysis for capacitive deionization

Capacitive deionization (CDI) devices use cyclical electrosorption on porous electrode surfaces to achieve water desalination. Process modeling and design of CDI systems requires accurate treatment of the coupling among input electrical forcing, input flow rates, and system responses including salt removal dynamics, water recovery, energy storage, and dissipation. Techno-economic analyses of CDI further require a method to calculate and compare between a produced commodity (e.g. desalted water) versus capital and operational costs of the system. In this work, we demonstrate a new modeling and analysis tool for CDI developed as an installable Matlab program that allows direct numerical simulation of CDI dynamics and calculation of key performance and cost parameters. The program is provided for free and is used to run open-source Simulink models. The Simulink environment sends information to the program and allows for a drag and drop design space where users can connect CDI cells to relevant periphery blocks such as grid energy, battery, solar panel, waste disposal, and maintenance/labor cost streams. The program allows for simulation of arbitrary current forcing and arbitrary flow rate forcing of one or more CDI cells. We employ validated well-mixed reactor formulations together with a non-linear circuit model formulation that can accommodate a variety of electric double layer sub-models (e.g. for charge efficiency). The program includes a graphical user interface (GUI) to specify CDI plant parameters, specify operating conditions, run individual tests or parameter batch-mode simulations, and plot relevant results. The techno-economic models convert among dimensional streams of species (e.g. feed, desalted water, and brine), energy, and cost and enable a variety of economic estimates including levelized water costs.

42 ENGINEERING↗
NASA NTRS2012

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth-to-Orbit Team (ETO) of the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) is considered the pre-eminent go-to group for pre-phase A and phase A concept definition. Over the past several years the ETO team has evaluated thousands of launch vehicle concept variations for a significant number of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Augustine Report, Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). The ACO ETO Team is called upon to address many needs in NASA s design community; some of these are defining extremely large trade-spaces, evaluating advanced technology concepts which have not been addressed by a large majority of the aerospace community, and the rapid turn-around of highly time critical actions. It is the time critical actions, those often limited by schedule or little advanced warning, that have forced the five member ETO team to develop a design process robust enough to handle their current output level in order to meet their customer s needs. Based on the number of vehicle concepts evaluated over the past year this output level averages to four completed vehicle concepts per day. Each of these completed vehicle concepts includes a full mass breakdown of the vehicle to a tertiary level of subsystem components and a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. A structural analysis of the vehicle to determine flight loads based on the trajectory output, material properties, and geometry of the concept is also performed. Due to working in this fast-paced and sometimes rapidly changing environment, the ETO Team has developed a finely tuned process to maximize their delivery capabilities. The objective of this paper is to describe the interfaces between the three disciplines used in the design process: weights and sizing, trajectory, and structural analysis. The tools used to perform such analysis are INtegrated Rocket Sizing (INTROS), Program to Optimize Simulated Trajectories (POST), and Launch Vehicle Analysis (LVA) respectively. The methods each discipline uses to streamline their particular part of the design process will also be discussed.

Waters, Eric D.↗
NASA NTRS2013

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth-to-Orbit Team (ETO) of the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) is considered the pre-eminent "go-to" group for pre-phase A and phase A concept definition. Over the past several years the ETO team has evaluated thousands of launch vehicle concept variations for a significant number of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Augustine Report, Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). The ACO ETO Team is called upon to address many needs in NASA's design community; some of these are defining extremely large trade-spaces, evaluating advanced technology concepts which have not been addressed by a large majority of the aerospace community, and the rapid turn-around of highly time critical actions. It is the time critical actions, those often limited by schedule or little advanced warning, that have forced the five member ETO team to develop a design process robust enough to handle their current output level in order to meet their customer's needs. Based on the number of vehicle concepts evaluated over the past year this output level averages to four completed vehicle concepts per day. Each of these completed vehicle concepts includes a full mass breakdown of the vehicle to a tertiary level of subsystem components and a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. A structural analysis of the vehicle to determine flight loads based on the trajectory output, material properties, and geometry of the concept is also performed. Due to working in this fast-paced and sometimes rapidly changing environment, the ETO Team has developed a finely tuned process to maximize their delivery capabilities. The objective of this paper is to describe the interfaces between the three disciplines used in the design process: weights and sizing, trajectory, and structural analysis. The tools used to perform such analysis are INtegrated Rocket Sizing (INTROS), Program to Optimize Simulated Trajectories (POST), and Launch Vehicle Analysis (LVA) respectively. The methods each discipline uses to streamline their particular part of the design process will also be discussed.

Waters, Eric D.↗
NASA NTRS2012

The Application of the NASA Advanced Concepts Office, Launch Vehicle Team Design Process and Tools for Modeling Small Responsive Launch Vehicles

The Advanced Concepts Office (ACO) Launch Vehicle Team at the NASA Marshall Space Flight Center (MSFC) is recognized throughout NASA for launch vehicle conceptual definition and pre-phase A concept design evaluation. The Launch Vehicle Team has been instrumental in defining the vehicle trade space for many of NASA s high level launch system studies from the Exploration Systems Architecture Study (ESAS) through the Augustine Report, Constellation, and now Space Launch System (SLS). The Launch Vehicle Team s approach to rapid turn-around and comparative analysis of multiple launch vehicle architectures has played a large role in narrowing the design options for future vehicle development. Recently the Launch Vehicle Team has been developing versions of their vetted tools used on large launch vehicles and repackaged the process and capability to apply to smaller more responsive launch vehicles. Along this development path the LV Team has evaluated trajectory tools and assumptions against sounding rocket trajectories and air launch systems, begun altering subsystem mass estimating relationships to handle smaller vehicle components, and as an additional development driver, have begun an in-house small launch vehicle study. With the recent interest in small responsive launch systems and the known capability and response time of the ACO LV Team, ACO s launch vehicle assessment capability can be utilized to rapidly evaluate the vast and opportune trade space that small launch vehicles currently encompass. This would provide a great benefit to the customer in order to reduce that large trade space to a select few alternatives that should best fit the customer s payload needs.

Threet, Grady E.↗
NASA NTRS2013

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth to Orbit (ETO) Team of the Advanced Concepts Office (ACO) at NASA Marshal Space Flight Center (MSFC) is considered the preeminent group to go to for prephase A and phase A concept definition. The ACO team has been at the forefront of a multitude of launch vehicle studies determining the future direction of the Agency as a whole due, in part, to their rapid turnaround time in analyzing concepts and their ability to cover broad trade spaces of vehicles in that limited timeframe. Each completed vehicle concept includes a full mass breakdown of each vehicle to tertiary subsystem components, along with a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. Additionally, a structural analysis of the vehicle based on material properties and geometries is performed as well as an analysis to determine the flight loads based on the trajectory outputs. As mentioned, the ACO Earth to Orbit Team prides themselves on their rapid turnaround time and often need to fulfill customer requests within limited schedule or little advanced notice. Due to working in this fast paced environment, the ETO team has developed some finely honed skills and methods to maximize the delivery capability to meet their customer needs. This paper will describe the interfaces between the 3 primary disciplines used in the design process; weights and sizing, trajectory, and structural analysis, as well as the approach each discipline employs to streamline their particular piece of the design process.

Waters, Eric D.↗
NASA NTRS2009

Improving Tools and Processes in Mechanical Design Collaboration

Cooperative product development projects in the aerospace and defense industry are held hostage to high cost and risk due to poor alignment of collaborative design tools and processes. This impasse can be broken if companies will jointly develop implementation approaches and practices in support of high value working arrangements. The current tools can be used to better advantage in many situations and there is reason for optimism that tool vendors will provide significant support.

Briggs, Clark↗
NASA NTRS1997

Computational Approaches to Interface Design

Tools which make use of computational processes - mathematical, algorithmic and/or knowledge-based - to perform portions of the design, evaluation and/or construction of interfaces have become increasingly available and powerful. Nevertheless, there is little agreement as to the appropriate role for a computational tool to play in the interface design process. Current tools fall into broad classes depending on which portions, and how much, of the design process they automate. The purpose of this panel is to review and generalize about computational approaches developed to date, discuss the tasks which for which they are suited, and suggest methods to enhance their utility and acceptance. Panel participants represent a wide diversity of application domains and methodologies. This should provide for lively discussion about implementation approaches, accuracy of design decisions, acceptability of representational tradeoffs and the optimal role for a computational tool to play in the interface design process.

Corker↗
NASA NTRS2003

Modeling and Simulation for Mission Operations Work System Design

Work System analysis and design is complex and non-deterministic. In this paper we describe Brahms, a multiagent modeling and simulation environment for designing complex interactions in human-machine systems. Brahms was originally conceived as a business process design tool that simulates work practices, including social systems of work. We describe our modeling and simulation method for mission operations work systems design, based on a research case study in which we used Brahms to design mission operations for a proposed discovery mission to the Moon. We then describe the results of an actual method application project-the Brahms Mars Exploration Rover. Space mission operations are similar to operations of traditional organizations; we show that the application of Brahms for space mission operations design is relevant and transferable to other types of business processes in organizations.

Sierhuis, Maarten↗
NASA NTRS1982

Development of the structural technology of a large deployable antenna

The current NASA-sponsored Antenna Technology Development Program of the offset wrap-rib antenna concept is based on a ground test program of 'proof of concept' hardware whose potential on-orbit performance is based on analytical estimates. The ground demonstration hardware represents a partial 55-meter diameter reflector and feed support structure. Testing will include automated deployment, reflector surface quality evaluation and validation of analytical performance models. Test results and hardware fabrication costs will be used to refine the models that will be the basis for the preliminary design of a 100-meter diameter wrap-rib antenna system. Additionally, the design, processes, tooling, fabrication techniques, fixturing and assembly approaches used for the 'proof of concept' hardware are directly applicable to building flight systems up to 100 meters in diameter.

Wada, B. K.↗
NASA NTRS2006

An Overview of the Role of Systems Analysis in NASA's Hypersonics Project

NASA's Aeronautics Research Mission Directorate recently restructured its Vehicle Systems Program, refocusing it towards understanding the fundamental physics that govern flight in all speed regimes. Now called the Fundamental Aeronautics Program, it is comprised of four new projects, Subsonic Fixed Wing, Subsonic Rotary Wing, Supersonics, and Hypersonics. The Aeronautics Research Mission Directorate has charged the Hypersonics Project with having a basic understanding of all systems that travel at hypersonic speeds within the Earth's and other planets atmospheres. This includes both powered and unpowered systems, such as re-entry vehicles and vehicles powered by rocket or airbreathing propulsion that cruise in and accelerate through the atmosphere. The primary objective of the Hypersonics Project is to develop physics-based predictive tools that enable the design, analysis and optimization of such systems. The Hypersonics Project charges the systems analysis discipline team with providing it the decision-making information it needs to properly guide research and technology development. Credible, rapid, and robust multi-disciplinary system analysis processes and design tools are required in order to generate this information. To this end, the principal challenges for the systems analysis team are the introduction of high fidelity physics into the analysis process and integration into a design environment, quantification of design uncertainty through the use of probabilistic methods, reduction in design cycle time, and the development and implementation of robust processes and tools enabling a wide design space and associated technology assessment capability. This paper will discuss the roles and responsibilities of the systems analysis discipline team within the Hypersonics Project as well as the tools, methods, processes, and approach that the team will undertake in order to perform its project designated functions.

Robinson, Jeffrey S.↗
DOE OSTI2021

Multi-Process Tooling

Decisions made early in the automotive design process influence material selection, which in turn dictates process selection and tool design. Because of tool build time and cost of tooling, the original path is not easily altered, even if there is compelling evidence that another material or process would be beneficial. This project focused on tool design that is agile enough to allow its use in multiple processes—injection, injection compression, and extrusion-compression. This tool design allows for the manufacture of components with the most efficient process or materials, without building multiple, single-process tools. The primary purpose of the Multi-Process Tool project was to physically demonstrate that a single, well-designed tool could be used to manufacture parts with a variety of materials that require different processes. A multi-process tool would be beneficial to providing data for any changes to the process since materials and processes can be interchanged without incurring additional tool cost(s). Battery tray parts, (representative of a multi-process tool, were successfully manufactured using various types of materials, such as fiber reinforced (carbon fiber and/or glass fibers, recycled carbon fibers), amorphous (PP, TPU), semi-crystalline (PA6, PA66), and crystalline (thermoset epoxy resin) polymers. Processing of the parts was achieved by injection molding, compression molding, compression overmolding, and injection overmolding. Specimens extracted from various locations on the battery tray parts were evaluated for mechanical properties (flexure and interlaminar shear strength properties). The results show that the tool can be used to produce parts from a wide range of materials and processes with no degradation of the physical or cosmetic properties.

42 ENGINEERING↗
NASA NTRS1996

Investigation of Machine Design for Friction Stir Welding

The process of joining two pieces of metal together has not significantly changed over the last few decades. The basic idea used is to bring the pieces together and apply enough heat to melt the metal at the interface. The molten metal mixes and after cooling forms a strong joint. This process is called the fusion process. The most significant difference between the many fusion processes is how the heat is generated and applied. The Welding Institute (TWI), in Great Britain, has recently patented an innovative application of mechanical friction. TWI designed a tool and process called Friction Stir Welding (FSW) that uses friction to heat the metal to within a few hundred degrees Fahrenheit of melting, just to the point of being plastic-like. The tool then stirs the plasticized metal together forming a joint that has been shown to be as good or better than an equivalent fusion joint. The FSW process is well suited for the joining of the aluminum alloys used in the aerospace industry. The relatively low melting point of aluminum eliminates the requirements for exotic materials for pin tool design. The FSW process has been successfully used to join alloys such as 7075 which were before considered "unweldable", and aluminum-lithium 2195 which exhibits many problems when fusion welded. The objective this summer was to investigate the design of a FSW system that could take this process from the laboratory to the manufacturing floor. In particular, it was the goal of my NASA colleague to develop a concept for applying the FSW process to the manufacturing of aluminum cryogenic oxygen and hydrogen tanks, of the sort used to make the Shuttle External Tank.

Romine, Peter L.↗
DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗
NASA NTRS1993

A dataflow analysis tool for parallel processing of algorithms

A graph-theoretic design process and software tool is presented for selecting a multiprocessing scheduling solution for a class of computational problems. The problems of interest are those that can be described using a dataflow graph and are intended to be executed repetitively on a set of identical parallel processors. Typical applications include signal processing and control law problems. Graph analysis techniques are introduced and shown to effectively determine performance bounds, scheduling constraints, and resource requirements. The software tool is shown to facilitate the application of the design process to a given problem.

Jones, Robert L., III↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗