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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Affordable Design: A Methodolgy to Implement Process-Based Manufacturing Cost into the Traditional Performance-Focused Multidisciplinary Design Optimization

The primary objective of this paper is to demonstrate the use of process-based manufacturing and assembly cost models in a traditional performance-focused multidisciplinary design and optimization process. The use of automated cost-performance analysis is an enabling technology that could bring realistic processbased manufacturing and assembly cost into multidisciplinary design and optimization. In this paper, we present a new methodology for incorporating process costing into a standard multidisciplinary design optimization process. Material, manufacturing processes, and assembly processes costs then could be used as the objective function for the optimization method. A case study involving forty-six different configurations of a simple wing is presented, indicating that a design based on performance criteria alone may not necessarily be the most affordable as far as manufacturing and assembly cost is concerned.

Bao, Han P.↗
NASA NTRSDate not supplied

Coarsening Up: Expanding the Particle Size Distributions of Lunar Simulants to Encompass A Comprehensive Range of Regolith Granularity

Due to a paucity of lunar regolith samples, simulated granular materials (simulants) have been developed and deployed for a variety of engineering and research purposes in an attempt to meet the requirements for lunar exploration. Broadly speaking, these manufactured materials aim to replicate the compositional (i.e., mineralogy and chemistry) and physical (e.g., particle size distribution, particle shape) profiles of lunar soil samples collected during the Apollo missions. While creating a “near-perfect” lunar simulant is prohibitive due to the unique formative processes (i.e., meteorite impacts, solar wind implantation) and conditions (anhydrous, reducing environment and exposure to radiation on the surface over billions of years) encountered on the moon, certain granular properties of the regolith can be recreated with a high level of fidelity by leveraging contemporary technologies. A fundamental physical property and descriptor, grain size can be correlated between samples and replicated through processing; however, a holistic understanding of the particle size distribution of lunar regolith must be considered when creating analog materials. This study produces particle size distributions for Apollo 16 returned samples, incorporating the sieved out >1 cm coarse-grained fraction, in order to provide a more comprehensive characterization of surficial lunar regolith grain sizes for the development of highlands-type granular analog testing materials.

R. N. Kovtun↗
DOE OSTI2026

Hygrothermal Performance of Bio-Based Materials in Residential Building Wall Envelope Systems

In the United States, building envelope systems contribute approximately 28% of building energy consumption, with walls being a primary factor. As the construction industry explores new approaches to lower the energy intensity needed to manufacture materials and, in turn, reduce energy consumption, bio-based materials are gaining attention as a promising alternative. While prior studies have demonstrated that bio-based materials can decrease material energy intensity, their long-term hygrothermal behavior within a whole residential wall system is not yet fully understood. This study aims to evaluate the potential of replacing Oriented Strand Board (OSB) and drywall in residential wall systems with bio-based alternatives. The research focuses on two bio-based materials, assessing their hygrothermal performance under Chicago climate condition (Climate Zone 5). To achieve that, a series of laboratory experiments were conducted to measure key properties of the bio-based materials such as thickness, dimensions, density, thermal conductivity (as a function of temperature and humidity), moisture-dependent permeance and water vapor permeability (WVP), and sorption isotherms. These properties were then used in WUFI® simulations to predict the moisture durability of a standard residential wall system in Climate Zone 5. Results show that substituting OSB and drywall with bio-based materials can achieve acceptable moisture durability, effectively mitigating risks of mold growth and structural damage over time.

Palani, Hevar [ORNL] (ORCID:0000000220211994)↗
NASA NTRS2012

Materials, Structures and Manufacturing: An Integrated Approach to Develop Expandable Structures

Membrane dominated space structures are lightweight and package efficiently for launch; however, they must be expanded (deployed) in-orbit to achieve the desired geometry. These expandable structural systems include solar sails, solar power arrays, antennas, and numerous other large aperture devices that are used to collect, reflect and/or transmit electromagnetic radiation. In this work, an integrated approach to development of thin-film damage tolerant membranes is explored using advanced manufacturing. Bio-inspired hierarchical structures were printed on films using additive manufacturing to achieve improved tear resistance and to facilitate membrane deployment. High precision, robust expandable structures can be realized using materials that are both space durable and processable using additive manufacturing. Test results show this initial work produced higher tear resistance than neat film of equivalent mass. Future research and development opportunities for expandable structural systems designed using an integrated approach to structural design, manufacturing, and materials selection are discussed.

Belvin, W. Keith↗
DOE OSTI2022

Probing the role of solids loading and mix procedure on the properties of acoustically mixed materials for additive manufacturing

We report resonant acoustic mixing has been of particular interest for use in additive manufacturing since viscous, solids-loaded materials can be difficult to mix and inhomogeneity has adverse effects on print quality. In this study, we detail a method to iterate through different formulations and mix procedures and assess mixture quality. The approach utilizes a constant pressure-driven flow test to collect statistics on flow rate through a standard geometry. This test is first applied to well mixed formulations containing particulate solids and find that the results are sensitive to viscosity produced by solids content. We then consider the formulations at various stages of mixing and find that the spread in the volume measurements is indicative of the mixing quality; poorly mixed material yields measurements with wide distributions. We believe this testing approach can be useful when screening new formulations, developing mixing processes, or for quality control.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Revealing conductivity of p-type delta layer systems for novel computing applications

This project uses a quantum simulation technique to reveal the true conducting properties of novel atomic precision advanced manufacturing materials. With Moore's law approaching the limit of scaling for the CMOS technology, it is crucial to provide the best computing power and resources to National Security missions. Atomic precision advanced manufacturing-based computing systems can become the key to the design, use, and security of modern weapon systems, critical infrastructure, and communications. We will utilize the state-of-the-art computational methodology to create a predictive simulator for p-type atomic precision advanced manufacturing systems, which may also find applications in counterfeit detection and anti-tamper.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

DETERMINATION OF THE SOLID-STATE RESISTANCE-WELDABILITY OF ADDITIVELY MANUFACTURED 304L STAINLESS STEEL

Additive manufacturing of pressure-containing boundaries is of interest to numerous industries, so a project was initiated to develop several different methods to join and weld additively manufactured materials. The approach investigated in this study was a low energy, solid state spot weld. This general approach has been routinely used for conventionally prepared tubing and is now being expanded to additively manufactured components. Additively manufactured 304L stainless steel sheets, semi-tubes, and tubes were resistance spot welded and compared to comparable welds in conventionally manufactured tubing. Radiographic computed tomography and metallography were used to evaluate the suitability of the welds using three criteria: weld closure length, thickness, and width. All additively manufactured test welds closely matched the conventional tubing for these criteria

additive manufacturing↗
DOE OSTI2024

The development of an augmented machine learning approach for the additive manufacturing of thermoelectric materials

Through the integration of machine learning (ML) techniques alongside additive manufacturing (AM) experimentation, we demonstrate an iterative process to rapidly predict laser-material interactions and melt pool geometries throughout the build parameter space for a bismuth telluride thermoelectric (TE) material. In doing so, we determined process parameters that created crack-free, highly dense (>99 %) n-type bismuth telluride (Bi 2 Te 2.7 Se 0.3 ) parts through laser powder bed fusion (LPBF). Furthermore, the ML-assisted understanding of the processing space allowed for the identification of build parameters that successfully yielded geometrically enhanced Bi 2 Te 2.7 Se 0.3 parts with reduced build times and no increase in experimental effort.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Promoting the regulatory acceptance of combined ion and neutron irradiation for material degradation in nuclear reactors

The Advanced Materials and Manufacturing Technologies (AMMT) program within the Department of Energy (DOE) Office of Nuclear Energy has developed its current recommendation for promoting the use of combined ion irradiation and neutron irradiation for the accelerated qualification of materials to be deployed in nuclear reactors. This plan is intended to provide a collaborative path forward that can be adopted by academia, national laboratories, and industry, and has been developed with input from the regulatory research arm of the U.S. Nuclear Regulatory Commission (NRC). To deploy new materials or materials manufactured with new technologies, such as additive manufacturing, materials must be evaluated for reactor-induced degradation from the combination of harsh temperatures, corrosive environments, and radiation fields. However, rapid deployment of materials necessitates accelerated testing methods rather than relying on years of neutron irradiation in a material test reactor. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. This presentation provides context governing both the scientific and regulatory aspects of the proposed goal. The discussion is aimed at a broad audience including researchers from industry, national laboratories, and academia. The recommended path forward is presented as a conceptual framework of specific steps. In brief, the strategy entails developing an integrated ion and neutron irradiation test plan for the material property of interest based on the fundamental tenet of the linkage of microstructure and properties in materials. Physics-based modeling interprets ion irradiation data and predicts neutron irradiation microstructure and properties with uncertainty bounds. The first round of testing is sufficient for an initial licensing application using a risk-informed approach, while a minimum required neutron irradiation test plan reduces cost and time requirements. A surveillance program with witness specimens in-reactor provides additional data over time to improve model predictions to higher damage levels and further reduce uncertainty bounds, which can be used for license extensions or longer lifetimes in new license applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRSDate not supplied

Reusable TPS Materials Development Activities at NASA Ames

Recent developments in low-cost access to low-earth orbit (LEO) and hypersonic flight are driving renewed demand in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Modern systems will need to consider full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance to enable this new generation of space flight. NASA Ames Research Center (ARC) has a long history of RTPS development including modern state-of-the-art materials like Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). Now, ARC is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts at ARC that span updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Adam Caldwell↗
DOE OSTI2023

Fastener joint and associated method for avoiding corrosion of dissimilar material fastener joints

A fastener for use in joining dissimilar materials manufactured by the process of producing the fastener with an external surface that forms an electrically insulating oxide layer when subjected to oxidation and, after manufacture and prior to use, subjecting the fastener to a pre-oxidation process to grow the desired oxide layer in situ on the external surface of the fastener. The present invention also provides a dissimilar material joint in which the pre-oxidized fastener is used to mechanically join dissimilar materials with the oxide layer electrically insulating the fastener from at least one of the dissimilar materials. The fastener may be a rivet used in friction self-piercing riveting (F-SPR). The fastener may be fabricated from an alloy capable of forming Al 2 O 3 or Cr 2 O 3 by thermal oxidation. The fastener may be pre-coated with Al or Cr that functions as a seed layer to form Al 2 O 3 or Cr 2 O 3 .

Lim, Yong Chae↗
NASA NTRS1996

Development of Y-Ba-Cu-O Superconductors for Magnetic Bearings

The material requirements, material manufacturing and magnetic properties that are relevant to fabrication of High Temperature Superconductor (HTS) magnetic bearings have been discussed. It is found that the seeded-melt-texturing method can be used to fabricate the single domain material that is required to achieve the best magnetic properties. Trapped-field mapping has been used as a non-destructive tool to determine the single-domain nature of the HTS material and quantity of the HTS disks. Both the trapped field and the levitation force of the Y-Ba-Cu-O disks are found to be strongly sensitive to the oxygen content.

Selvamanickam, V.↗
NASA NTRS2018

In-Space Manufacturing at NASA Marshall Space Flight Center: A Portfolio of Fabrication and Recycling Technology Development for the International Space Station

The in-space manufacturing project at NASA Marshall Space Flight Center seeks to mature the manufacturing capabilities which will be needed on long duration, long endurance human spaceflight missions. The ability to manufacture materials and parts in space rather than launching them from earth has the potential to reduce logistics requirements and enhance crew safety. The International Space Station serves as a unique orbiting test bed for in-space manufacturing technology development for NASA and its commercial partners. This paper provides an overview of the projects currently in the in-space manufacturing technology portfolio and key technology development efforts in the past year.

Prater, Tracie↗
NASA NTRS1993

New textile composite materials development, production, application

New textile composite materials development, production, and application are discussed. Topics covered include: super-high-strength, super-high-modulus fibers, filaments, and materials manufactured on their basis; heat-resistant and nonflammable fibers, filaments, and textile fabrics; fibers and textile fabrics based on fluorocarbon poylmers; antifriction textile fabrics based on polyfen filaments; development of new types of textile combines and composite materials; and carbon filament-based fabrics.

Mikhailov, Petr Y.↗
NASA NTRS2008

On-Site Fabrication Infrastructure to Enable Efficient Exploration and Utilization of Space

Unlike past one-at-a-time mission approaches, system-of-systems infrastructures will be needed to enable ambitious scenarios for sustainable future space exploration and utilization. So what do we do when we get to the moon for sustainable exploration. On-site fabrication infrastructure will be needed to support habitat structure development, tools and mechanical part fabrication, as well as repair and replacement of ground support and space mission hardware such as life support items, vehicle components and crew systems. The on-site fabrication infrastructure will need the In Situ Fabrication and Repair (ISFR) element, which is working in conjunction with the In Situ Resources Utilization (ISRU) element, to live off the land. The ISFR element has worked closely with the ISRU element in the past year to assess the ability of using lunar regolith as a viable feedstock for fabrication material. Preliminary work has shown promise and the ISFR Element will continue to concentrate on this activity. Fabrication capabilities have been furthered with the process certification effort that, when completed, will allow for space-qualified hardware to be manufactured. Materials being investigated include titanium and aluminum alloys as well as lunar regolith simulants with binders. This paper addresses the latest advancements made in the fabrication of infrastructures that support efficient, affordable, reliable infrastructures for both space exploration systems and logistics; infrastructures that allow sustained, affordable and highly effective operations on the Moon and beyond.

Howell, Joe T.↗
DOE OSTI2024

Li-ion battery design through microstructural optimization using generative AI

Lithium-ion batteries are used across various applications, necessitating tailored cell designs to enhance performance. Optimizing electrode manufacturing parameters is a key route to achieving this, as these parameters directly influence the microstructure and performance of the cells. However, linking process parameters to performance is complex, and experimental or modeling campaigns are often slow and expensive. This study introduces a fast computational optimization framework for electrode manufacturing parameters. A generative model, trained on a small dataset of microstructural images associated with different manufacturing parameters, efficiently generates representative microstructures for new parameters. This model is integrated into a Bayesian optimization loop that includes microstructure generation, characterization, and simulation, aiming to find optimal manufacturing parameters for a particular application. Significant improvement in the energy density of a 4680 cell is achieved through bespoke cell design, highlighting the importance of cell-scale normalization. The framework’s modularity allows its application to various advanced materials manufacturing scenarios.

batteries↗
NASA NTRS1981

Survey of the US materials processing and manufacturing in space program

To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.

Mckannan, E. C.↗
DOE OSTI2026

Embedding Fiber Optic Sensors in Stainless Steel using Spark Plasma Sintering for Structural Health Monitoring in Harsh Environments

Embedded fiber optic sensors such as fiber Bragg gratings (FBGs) offer a unique route for distributed real-time in-situ imaging of various engineering parameters for numerous purposes. This study advanced the current sensor embedding approaches by exploring a spark plasma sintering (SPS)-assisted technology to embed FBGs in high-temperature structural materials and demonstrated the capability of temperature measurement. In this approach, single-mode FBGs were integrated into stainless steel (SS) 316L components using SPS, followed by the evaluation of the bonding quality between the FBGs and matrix, the optical attenuation of the fibers induced by embedding, and the sensing characters of the FBGs under temperature stimuli. The results demonstrated that superior bonding was achieved between the FBGs and highly-densified SS316L. Examination of the behavior of Bragg gratings validated signal fidelity after embedding. Real-time thermal imaging under temperature cycling using the FBGs demonstrated the effectiveness of the technique for smart materials manufacturing.

36 - MATERIALS SCIENCE↗