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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 271 records · Page 15

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DOE OSTI2025

Tensile Performance Sensitivity to Variations of Standard 17-4 PH Heat Treatments on LPBF-Produced Material

Standard heat treatments for metals of a particular composition are typically designed with the assumption of a conventional starting microstructure, such as that produced by casting or wrought processing. When applied to metals fabricated by Laser Powder Bed Fusion (LPBF) metal additive manufacturing (AM), these heat treatments can produce inconsistent performance due to the unique as-built microstructures. This study investigates how modifications to standard heat treatments for 17-4 PH steel influence the microstructure and mechanical properties of LPBF-fabricated material. Specimens were produced and subjected to varying solutionizing and homogenizing treatments followed by standard aging treatments. Microstructures were characterized using optical microscopy, Electron Backscatter Diffraction (EBSD), and X-ray diffraction (XRD), and mechanical properties were evaluated through uniaxial tensile testing. Based on these results, recommendations are provided for achieving improved wrought-like performance in LPBF 17-4 PH steel.

17-4 PH↗

DOE OSTI2025

Experimental and numerical evaluation of laser shinethrough in polystyrene at 3 ω and 4 ω laser frequencies

In laser-direct-drive inertial confinement fusion (ICF), laser shinethrough is the process associated with laser propagation through the target plastic ablator, polystyrene is often used in ICF experiments, and leads to energy deposition in the target until the critical density is established at the ablator front surface. This process causes material modifications that may change the shock propagation and lead to density and pressure perturbations at the interface between the polystyrene and cryogenic deuterium-tritium (DT) layer. This work reports on experimental observations and numerical investigations of laser shinethrough at the third and the fourth harmonic of ICF class laser systems (1 ω corresponds to a wavelength of ∼1.06 μm ). The experiments evidence that, at 4 ω , the laser is absorbed over a distance of about a few microns and laser shinethrough is completely eliminated in contrast with the behavior at 3 ω . These experimental observations are reproduced by numerical simulations. The laser fluence required to reach the critical density at the ablator front surface is also found to be more than one order of magnitude higher at the third harmonic. Finally, modeling suggests that the back surface of the ablator exhibits ion temperatures greater than the melting temperature of cryogenic DT and electron pressure larger than the bulk and shear moduli of cryogenic DT for the case of using a 3 ω laser.

Pineau, A. [Univ. of Rochester, NY (United States)↗

NASA NTRS2000

The Electrostatic Levitation Facility at NASA's Marshall Space Flight Center

Containerless processing is an important area of research in materials science. Electrostatic levitation (ESL) represents an emerging technology which permits containerless processing in a vacuum environment. NASA's Marshall Space Flight Center (MSFC) established a levitation facility to provide a critical resource to the microgravity materials science research community to continue and enhance ground-based research in the support of the development of flight experiments during the transition to Space Station. During ESL processing, charged specimens are levitated in the electrostatic field produced by the system's electrodes. Three sets of positioning electrodes represent the heart of the MSFC system. Two dual-axis position sensitive detectors provide input for the PID control-loop computer. Sample position is maintained by adjusting the control voltages for the power supplies of the positioning electrodes. A UV source refreshes the charge on specimens during processing via the photoelectric effect. Lasers permit sample heating independent of positioning. The processing chamber typically operates under vacuum condition approximately = 10(exp -7) Torr. Electrostatic levitation provides a materials science research tool for investigations of refractory solids and melts. Topics of investigation include thermophysical properties, phase equilibria, metastable phase formation, undercooling and nucleation, time-temperature-transformation diagrams and other aspects of materials processing. Current capabilities and recent results of processing studies for metals, alloys and oxides will be reviewed.

Rogers, Jan R.↗

NASA NTRS1995

Oxide perovskite crystals for HTSC film substrates microwave applications

The research focused upon generating new substrate materials for the deposition of superconducting yttrium barium cuprate (YBCO) has yielded several new hosts in complex perovskites, modified perovskites, and other structure families. New substrate candidates such as Sr(Al(1/2)Ta(1/2))O3 and Sr(Al(1/2)Nb(1/2))O3, Ba(Mg(1/3)Ta(2/3))O3 in complex oxide perovskite structure family and their solid solutions with ternary perovskite LaAlO3 and NdGaO3 are reported. Conventional ceramic processing techniques were used to fabricate dense ceramic samples. A laser heated molten zone growth system was utilized for the test-growth of these candidate materials in single crystal fiber form to determine crystallographic structure, melting point, thermal, and dielectric properties as well as to make positive identification of twin free systems. Some of those candidate materials present an excellent combination of properties suitable for microwave HTSC substrate applications.

Bhalla, A. S.↗

NASA NTRS1985

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗

NASA NTRS1991

Optical processing using photorefractive GaAs and InP

The unique features of photorefractive compound semiconductors are presented. The advantages of this class of nonlinear optical materials for optical processing are illustrated with examples using GaAs and InP. The difference between GaAs and InP in the laser power density requirement is discussed.

Liu, Duncan T. H.↗

NASA NTRS1997

Super-Compact Laser

Microcosm, Inc. produced the portable Farfield-2 laser for field applications that require high power pulsed illumination. The compact design was conceived through research at Goddard Space Flight Center on laser instruments for space missions to carry out geoscience studies of Earth. An exclusive license to the key NASA patent for the compact laser design was assigned to Microcosm. The FarField-2 is ideal for field applications, has low power consumption, does not need water cooling or gas supplies, and produces nearly ideal beam quality. The properties of the laser also make it effective over long distances, which is one reason why NASA developed the technology for laser altimeters that can be toted aboard spacecraft. Applications for the FarField-2 include medicine, biology, and materials science and processing, as well as diamond marking, semiconductor line-cutting, chromosome surgery, and fluorescence microscopy.

Source record↗

NASA NTRS2019

Simulating Space Weathering in the Transmission Electron Microscope via Dynamic in Situ Heating and Helium Irradiation of Olivine

The chemical composition, microstructure, and optical properties of grains on the surfaces of airless bodies are predominantly altered by micrometeorite impacts and solar wind irradiation. These processes drive space weathering and result in the formation of features including chemically-altered, amorphous grain rims, Fe nanoparticles (npFe), and vesiculated grain textures. These characteristics have been identified in returned samples from the surfaces of the Moon and asteroid Itokawa. In order to advance our understanding of the formation of these microstructural and chemical features in returned samples, we have simulated space weathering processes for a variety of materials via laboratory experiments. These experiments include ion irradiation to simulate solar wind exposure and laser irradiation and in situ heating to simulate micrometeorite impacts. While these experiments have provided considerable insight into the formation mechanisms of many space weathering features, they are predominantly static and typically performed separately. Here we present results from the simulated space weathering of olivine grains via He irradiation and dynamic heating, both performed in situ inside the transmission electron microscope (TEM). These experiments allow for the real-time observation of chemical and microstructural changes resulting from the superposed effects of ion irradiation and pulsed heating.

Thompson, M. S.↗

NASA NTRSDate not supplied

Convolutional Neural Networks for Image Classification in Metal Selective Laser Meting Additive Manufacturing

Selective laser melting (SLM) is a metal additive manufacturing process that has several advantages such as the large range of metal materials that can be accommodated, 3D printing of complex shape components, the ability to adjust material properties, and cost reduction as expensive production equipment may not be required. Therefore, process monitoring is crucial in different stages of the component building. In this work, convolutional neural networks (CNNs) are investigated as a suitable technique for post-inspection of builds. The monitoring of manufactured parts was conducted by collecting computed tomography (CT) images and identifying defects. Five CNN models were implemented and tested for the classification of the CT images. The models were based on NASNetMobile and DenseNet121, and a custom built CNN model. The results of this work show that CNNs can be feasible and reliable for rapid monitoring and classification of defects in CT images from build fabrication using SLM.

Rodolfo Ledesma↗

DOE OSTI2024

Leveraging Calibration Transfer Techniques for Remote Monitoring of Samarium and Europium in LiCl Using Laser-Induced Florescence Spectroscopy for Radioisotope Production Applications

Radioisotope production relies on complex chemical processes that must be performed in radiological hot cells or glove boxes because of the radioactive and otherwise hazardous materials being used. In these situations, optical sensors can provide real-time monitoring to users, which is unobtainable by more traditional methods. This study explores the use of calibration transfer methods to train a model on one instrument and date and then transfer it to another instrument of the same or different configuration on a different date. By performing laser-induced fluorescence measurements of Eu(III) and Sm(III) in 10 M LiCl over the course of 6 months using two disparate spectrometers and two different training sets, a strategy for calibrating and deploying models for online monitoring was established. Three transfer techniques were compared: direct standardization (DS), piecewise direct standardization (PDS), and external parameter orthogonalization (EPO). DS and PDS outperformed EPO for day-to-day transfers, and EPO was not effective for instrument-to-instrument transfers. Transferring the initial date’s full factorial model provided better prediction performance compared with retraining models the day of measurements using a D-optimal designed calibration set. For both day-to-day and instrument-to-instrument transfers, five Kennard–Stone selected samples were sufficient. Based on this choice, the initial-date, high-resolution spectrometer model was transferred to a lower-resolution, compact spectrometer 6 months later to monitor a simulated, real-time demonstration. Here, the combined predictions of the DS and PDS transferred models were able to accurately track the anticipated concentration profiles, maintaining root-mean-square error of prediction values below 10 ppm.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Data-driven distortion compensation for laser powder bed fusion process using Gaussian process regression and inherent strain method

Not Available

Materials Science↗

NASA NTRS1983

Attitude Control by Localized Outgassing

Attitude control of levitated object achieved by using laser to vaporize selectively sublimate coating. Laser heats material that will sublime or outgas. To obtain torque reaction force vector from subliming material must not pass through center-of-mass of object. Laser provides beam suitable for controlling objects in noncontact manufacturing processes in acoustic levitation chambers.

Elleman, D. D.↗

NASA NTRS1988

Proposal for a lunar tunnel-boring machine

A need exists for obtaining a safe and habitable lunar base that is free from the hazards of radiation, temperature gradient, and micrometeorites. A device for excavating lunar material and simultaneously generating living space in the subselenian environment was studied at the conceptual level. Preliminary examinations indicate that a device using a mechanical head to shear its way through the lunar material while creating a rigid ceramic-like lining meets design constraints using existing technology. The Lunar Tunneler is totally automated and guided by a laser communication system. There exists the potential for the excavated lunar material to be used in conjunction with a surface mining process for the purpose of the extraction of oxygen and other elements. Experiments into lunar material excavation and further research into the concept of a mechanical Lunar Tunneler are suggested.

Allen, Christopher S.↗

NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗

NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Gradl, Paul↗

DOE OSTI2025

Methane pyrolysis by Joule heating for graphitic carbon and hydrogen production

The global energy transition toward sustainability requires technologies that can decarbonize energy carriers and fuels while producing valuable materials. Methane, a primary component of natural gas, is both a high-energy-density fuel and a significant greenhouse gas. This study reports an approach for methane pyrolysis utilizing Joule heating within the deposition substrate to drive the endothermic reaction. With electric current passing through a resistive porous carbon cloth, heat is generated to break C-H bonds of methane molecules. Here, the decomposition of methane as it flows through the cloth results in hydrogen production and the formation of conformally layered graphite around the carbon fibers. The effects of input power, chamber pressure, feedstock flow rate, and process duration on hydrogen and graphite production are characterized via in situ mass spectrometry and laser absorption spectroscopy, resulting in methane conversion rates up to 88%, with hydrogen and carbon yields of 82% and 72%, respectively. Material characterization verifies uniform high-quality graphite deposition, with a Raman I D /I G ratio of 0.1 and 3.38 Å d-spacing. This Joule heating method for catalyst-free methane pyrolysis offers the potential for advancing hydrogen production technology by simultaneously producing valuable materials such as solid graphite, thus enhancing the economic viability of the fuel decarbonization process.

Energy Resources↗

NASA NTRS2000

Development and Testing of Cooled CMCs for High Thermal Flux Applications

Ceramic Matrix Composites (CMCS) offer the potential for significant weight savings and improved performance for a range of propulsion components utilizing refractory materials. This paper describes the fabrication and testing of functionally graded CMCs produced via a low cost process that represents an order of magnitude cost savings over conventionally fabricated CMCS. Test cylinders were fabricated, characterized and evaluated during exposure to high thermal fluxes of up to 10MW/meters squared at the Laser Hardened Materials Evaluation Laboratory (LHMEL). The bulk density of the CMC tubes was approximately 2.2 grams per cubic centimeters. The performance of cryogenically cooled CMCs was compared with uncooled CMCs against similar thermal loads, and fundamental property data collected for this relatively new breed of CMC. Finally, test thrust cells were fabricated from the functionally graded composite and tested using liquid H2 and O2 propellants at NASA Glen.

Patterson , Mark↗