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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 199 records · Page 11

Nanometer flat blazed x-ray gratings using ion beam figure correction

With the development of nanometer accuracy stitching interferometry, ion beam figuring (IBF) of x-ray mirrors can now be achieved with unprecedented performance. However, the process of producing x-ray diffraction gratings on these surfaces may degrade the figure quality due to process errors introduced during the ruling of the grating grooves. To address this challenge, we have investigated the post-production correction of gratings using IBF, where stitching interferometry is used to provide in-process feedback. A concern with ion beam correction in this case is that ions will induce enough surface mobility of atoms to cause smoothing of the grating structure and degradation of diffraction efficiency. In this study we found however that it is possible to achieve a nanometer-level planarity of the global grating surface with IBF, while preserving the grating structure. The preservation was so good, that we could not detect a change in the diffraction efficiency after ion beam correction. This is of major importance in achieving ultra-high spectral resolution, and the preservation of brightness for coherent x-ray beams.

36 MATERIALS SCIENCE↗

Characterization of Lab-Grown Cracks for Aerosol Transmission Testing

Motivation: Determine the length and opening of two lab-grown cracks, designated as LT-14 and LT-28, representative of stress corrosion cracks in spent nuclear fuel dry storage casks to supplement future testing of gas and aerosol transport. Problem: The extreme aspect ratio of the crack length to opening requires that imaging occurs in stages with the results merged before final analysis. Method: High magnification (1500x) optical images of both sides of the two plates were acquired. 20x stitched images with LSCM were acquired, fully stitched along the length, and leveled with newly developed PLATES Method in MATLAB®. Conclusion for LT-14: Side 1 is 47.25 mm long and has 366 separate crack features with an average length of 23.50 µm and an average opening of 8.27 µm. Side 2 is 69.44 mm long and has 550 separate crack features with an average length of 81.63 µm and an average opening of 67.70 µm. Conclusion for LT-28: Side 1 is 71.95 mm long and has 1,127 separate crack features with an average length of 42.27 µm and an average opening of 10.31 µm. Side 2 is 74.88 mm long and has 520 separate crack features with an average length of 98.13 µm and an average opening of 14.99 µm. The adjacent crack on side 1 is 18.95 mm long and has 37 separate crack features with an average length of 17.46 µm and an average opening of 10.42 µm. The adjacent crack on side 2 is 26.40 mm long and has 55 separate crack features with an average length of 87.26 µm and an average opening of 48.29 µm. Each adjacent crack is approximately 26 mm from the main crack.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Convergence of Emerging Technologies - Blickfeld Test Results

The Blickfeld Cube 1 Lidar is an inexpensive flash lidar being developed for autonomous navigation with an advertised maximum range of 75 meters that uses a Class 1 eye-safe laser. Figure 1 shows an example of the installation of the Cube 1 lidar and Figure 2 shows an example of the point cloud generated, with the red circle indicating an intruder. The Cube 1 lidar has a software adjustable field of view and as many as 5 lidars can be stitched together. (Figure 2 shows two Cube 1 lidars stitched together.)

47 OTHER INSTRUMENTATION↗

Flavor Classification in ICARUS Using Convolutional Visual Networks

In this work, we adapt the Convolutional Visual Network (CVN) approach [1] to the ICARUS detector by incorporating TPC stitching methods inspired by NuGraph[8]. The stitching technique used here is unique to ICARUS, designed specifically to handle its distinct detector segmentations. We then retrain the network using ICARUS-specific data. This study underscores the flexibility of deep learning models in high-energy physics and the importance of accounting for detector-specific features when transferring machine learning techniques between experiments. This poster presents the methods, classification performance, and insights gained from applying CVN to ICARUS data.

Wieler, Felipe [Tech. Fed. Parana U.]↗

Intelligent Experiments through Real-Time AI: Fast Data Processing and Autonomous Detector Control for High-Energy Nuclear Experiments

The aim of this project is to develop software and hardware for fast real-time data processing and autonomous detector control and calibration for the sPHENIX and the future EIC experiments. Below summarizes Georgia Tech team efforts in the past year: 1. We developed a real-time clustering algorithm and FPGA-based pipeline architecture for processing fired pixel data from ALPIDE sensors in sPHENIX experiments. Our Columnar Clustering Co-Design introduces a hardware-aware, stream-friendly approach that segments pixel data by column pairs using a Column Pair Clustering (CPC) strategy, followed by Cluster Stitching to merge adjacent subclusters. Implemented in Vitis HLS, the pipeline comprises five stages—read-in, subclustering, stitching, analysis, and write-out—connected by tagged HLS streams with custom end-of-event signaling for robust synchronization. We designed a pipelined dataflow model optimized for throughput, low latency, and minimal buffering, enabling scalable clustering across events of arbitrary size. Our system maintains spatial precision via center-of-mass and shape key extraction and efficiently handles edge cases such as fragmented or nested clusters. Compared against DBSCAN in both software and hardware, our approach demonstrates competitive performance under FPGA constraints. 2. We also conducted a comprehensive algorithm-to-hardware co-design of connected component analysis tailored for sPHENIX experiments, focusing on real-time, low-latency processing using FPGAs and High-Level Synthesis (HLS). Starting from a Python-based particle tracking pipeline, the team translated the core logic—graph traversal via DFS and Union-Find—into an HLS-compatible C++ model, replacing dynamic memory and recursion with static arrays and pipelined control flow. The final design includes a fully streamed and dataflow-compatible Union-Find kernel optimized across five iterations, incorporating loop pipelining, array partitioning, AXI/FIFO interface tuning, and function flattening. Experimental results show up to 14.8× speedup over the CPU baseline, reducing per-graph latency to 1.58 μs and demonstrating strong resource efficiency with only ~7k LUTs and zero BRAM usage. The design maintains functional correctness against the Python reference using a Python-based C-simulation framework and Mean Squared Error metrics. This work validates the potential of HLS-driven FPGA designs for edge-level HEP data acquisition, laying a scalable foundation for future integration with real-time detector pipelines and multi-graph processing systems.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Improved heat-resistant garments

Fabrication method for protective clothing eliminates the common heat-short by avoiding the stitch which is common to all layers, and preventing external exposure of any stitch to the outer environment. A unique overlap arrangement is described and additional protective methods are discussed.

Johnston, R. S.↗

Method of repairing discontinuity in fiberglass structures

Damaged fiberglass structures are repaired by substantially filling the irregular surfaced damaged area with a liquid, self-curing resin, preferably an epoxy resin mixed with chopped fiberglass, and then applying to the resin surface the first of several woven fiberglass swatches which has stitching in a zig-zag pattern parallel to each of its edges and a fringe of warp and fill glass fibers about the edges outward of the stitching. The method is especially applicable to repair of fiberglass rocket engine casings and is particularly advantageous since it restores the repaired fiberglass structure to substantially its original strength without any significant changes in the geometry or mass of the structure.

Gelb, L. L.↗

On development of a sealed bearing for space suits

The work to correct several design deficiencies present in the bearings used in the orbital extravehicular spacesuit is reported. These deficiencies included: difficult stitch-on interface between fabric and outer race; a tendency for the clamping threads to seize; and, most importantly, the failure of the sealing surfaces (Teflon seat, Delrin seal) to maintain integrity with cycling. The first problem was corrected by raising the stitch-on holes so as to be more accessible. The seizing was eliminated by changing to a coarser thread, from 32/inch to 24/inch. The solution to the sealing problem required a materials evaluation, candidate material selection, and adhesive evaluation (for bonding the seat material to the outer race) and bench-cycling of candidate seal/seat combinations. The final configuration, successfully bench-cycled and delivered to NASA, is shown.

Rayfield, J.↗

Bonded Lockstitch for Insulating Blankets

Improved sewing technique for high-temperature insulating blankets prevents stitch failure in hot, turbulent environments. Standard lockstitch modified to isolate single-stitch failures. Bobbin thread kept at blanket surface. Silicone adhesive applied to all bobbin/needle intersections, so failure at one point will not propagate along thread. Suitable for use in aerodynamic and other applications where there is turbulence.

Rivin, J. M.↗

Aerodynamics of sports balls

Research data on the aerodynamic behavior of baseballs and cricket and golf balls are summarized. Cricket balls and baseballs are roughly the same size and mass but have different stitch patterns. Both are thrown to follow paths that avoid a batter's swing, paths that can curve if aerodynamic forces on the balls' surfaces are asymmetric. Smoke tracer wind tunnel tests and pressure taps have revealed that the unbalanced side forces are induced by tripping the boundary layer on the seam side and producing turbulence. More particularly, the greater pressures are perpendicular to the seam plane and only appear when the balls travel at velocities high enough so that the roughness length matches the seam heigh. The side forces, once tripped, will increase with spin velocity up to a cut-off point. The enhanced lift coefficient is produced by the Magnus effect. The more complex stitching on a baseball permits greater variations in the flight path curve and, in the case of a knuckleball, the unsteady flow effects. For golf balls, the dimples trip the boundary layer and the high spin rate produces a lift coefficient maximum of 0.5, compared to a baseball's maximum of 0.3. Thus, a golf ball travels far enough for gravitational forces to become important.

Mehta, R. D.↗

Low cost damage tolerant composite fabrication

The resin transfer molding (RTM) process applied to composite aircraft parts offers the potential for using low cost resin systems with dry graphite fabrics that can be significantly less expensive than prepreg tape fabricated components. Stitched graphite fabric composites have demonstrated compression after impact failure performance that equals or exceeds that of thermoplastic or tough thermoset matrix composites. This paper reviews methods developed to fabricate complex shape composite parts using stitched graphite fabrics to increase damage tolerance with RTM processes to reduce fabrication cost.

Palmer, R. J.↗

Net Catches Debris From Explosion

Device restrains fragments and absorbs their kinetic energy. Net of stitched webbing folds compactly over honeycomb plug. Attaches to frame mounted on wall around rectangular area to be cut out by explosion. Honeycomb panel absorbs debris from explosion and crumples into net. Dissipates energy by ripping about 9 in. of stitched net. Developed for emergency escape system in Space Shuttle, adaptable to restraint belts for vehicles; subjecting passengers to more gradual deceleration and less shock.

Kahn, Jon B.↗

Compression response of thick layer composite laminates with through-the-thickness reinforcement

Compression and compression-after-impact (CAI) tests were conducted on seven different AS4-3501-6 (0/90) 0.64-cm thick composite laminates. Four of the seven laminates had through-the-thickness (TTT) reinforcement fibers. Two TTT reinforcement methods, stitching and integral weaving, and two reinforcement fibers, Kevlar and carbon, were used. The remaining three laminates were made without TTT reinforcements and were tested to establish a baseline for comparison with the laminates having TTT reinforcement. Six of the seven laminates consisted of nine thick layers whereas the seventh material was composed of 46 thin plies. The use of thick-layer material has the potential for reducing structural part cost because of the reduced part count (layers of material). The compression strengths of the TTT reinforced laminates were approximately one half those of the materials without TTT reinforcements. However, the CAI strengths of the TTT reinforced materials were approximately twice those of materials without TTT reinforcements. The improvement in CAI strength is due to an increase in interlaminar strength produced by the TTT reinforcement. Stitched laminates had slightly higher compression and CAI strengths than the integrally woven laminates.

Farley, Gary L.↗

A mechanism responsible for reducing compression strength of through-the-thickness reinforced composite material

A study was conducted to identify one of the mechanisms that contributes to the reduced compression strength of composite materials with through-the-thickness (TTT) reinforcements. In this study a series of thick (0/90) laminates with stitched and integrally woven TTT reinforcements were fabricated and statically tested. In both the stitching and weaving process a surface loop of TTT reinforcement yarn is created between successive TTT penetrations. It was shown that the surface loop of the TTT reinforcement 'kinked' the in-plane fibers in such a manner that they were made ineffective in carrying compressive load. The improvement in strength by removal of the surface loop and 'kinked' in-plane fibers was between 7 and 35 percent.

Farley, Gary L.↗

Characterization of multiaxial warp knit composites

The objectives were to characterize the mechanical behavior and damage tolerance of two multiaxial warp knit fabrics to determine the acceptability of these fabrics for high performance composite applications. The tests performed included compression, tension, open hole compression, compression after impact and compression-compression fatigue. Tests were performed on as-fabricated fabrics and on multi-layer fabrics that were stitched together with either carbon or Kevlar stitching yarn. Results of processing studies for vacuum impregnation with Hercules 3501-6 epoxy resin and pressure impregnation with Dow Tactix 138/H41 epoxy resin and British Petroleum BP E905L epoxy resin are presented.

Dexter, H. Benson↗

Physical interpretation and development of ultrasonic nondestructive evaluation techniques applied to the quantitative characterization of textile composite materials

In this Progress Report, we describe our current research activities concerning the development and implementation of advanced ultrasonic nondestructive evaluation methods applied to the characterization of stitched composite materials and bonded aluminum plate specimens. One purpose of this investigation is to identify and characterize specific features of polar backscatter interrogation which enhance the ability of ultrasound to detect flaws in a stitched composite laminate. Another focus is to explore the feasibility of implementing medical linear array imaging technology as a viable ultrasonic-based nondestructive evaluation method to inspect and characterize bonded aluminum lap joints. As an approach to implementing quantitative ultrasonic inspection methods to both of these materials, we focus on the physics that underlies the detection of flaws in such materials.

Miller, James G.↗

Comparison of resin film infusion, resin transfer molding, and consolidation of textile preforms for primary aircraft structure

Innovative design concepts and cost effective fabrication processes were developed for damage tolerant primary structures that can perform at a design ultimate strain level of 6000 micro inch/inch. Attention focused on the use of textile high performance fiber reinforcement concepts that provide improved damage tolerance and out-of-plane load capability, low cost resin film infusion (RFI) and resin transfer molding (RTM) processes, and thermoplastic forming concepts. The fabrication of wing 'Y' spars by four different materials and/or processes methods is described: fabricated using IM7 angle interlock 0 to 90 deg woven preforms with + or - 45 deg plies stitched with Toray high strength graphite thread and processed using RFI and 3501-6 epoxy; fabricated using G40-800 knitted/stitched preforms and processed using RFI and 3501-6 epoxy; fabricated using G40-800 knitted/stitched preforms using RTM and Tactix 123/H41 epoxy; and fabricated preforms using AS4(6K)/PEEK 150 g commingled angle interlock 0 to 90 deg woven preforms with + or - 45 deg commingled plies stitched using high strength graphite thread and processed by consolidation. Structural efficiency, processability, and acquisition cost are compared.

Suarez, J.↗

Test methods for textile composites

Various test methods commonly used for measuring properties of tape laminate composites were evaluated to determine their suitability for the testing of textile composites. Three different types of textile composites were utilized in this investigation: two-dimensional (2-D) triaxial braids, stitched uniweave fabric, and three-dimensional (3-D) interlock woven fabric. Four 2-D braid architectures, five stitched laminates, and six 3-D woven architectures were tested. All preforms used AS4 fibers and were resin-transfer-molded with Shell RSL-1895 epoxy resin. Ten categories of material properties were investigated: tension, open-hole tension, compression, open-hole compression, in-plane shear, filled-hole tension, bolt bearing, interlaminar tension, interlaminar shear, and interlaminar fracture toughness. Different test methods and specimen sizes were considered for each category of test. Strength and stiffness properties obtained with each of these methods are documented in this report for all the material systems mentioned above.

Minguet, Pierre J.↗