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NASA NTRS2023

X-59 Sonic Boom Test Results from the NASA Glenn 8- by 6-Foot Supersonic Wind Tunnel

A wind tunnel test was conducted to investigate near-field sonic boom pressure signatures of the X-59 Low-Boom Flight Demonstrator aircraft. A 1.62%-scale model of the aircraft was fabricated for the wind tunnel test, which took place in the NASA Glenn 8- by 6-Foot Supersonic Wind Tunnel in September and October 2021. The model had provisions for being mounted by a swept blade strut that attached at top of model ahead of the inlet, or by a rear-entry sting that held the model at the location of the nacelle. The model had alternate parts for ±0.5° deflections of the flaps, ailerons, and stabilator, and ±1° deflections of the T-tail. Off-body static pressure measurements of the flow field below the model were made on a pressure rail which had 420 orifices along its tip. The model was positioned at various heights from the rail by vertical movement of the tunnel strut, and at various longitudinal stations relative to the rail by means of a linear actuator mounted between the wind tunnel strut and the balance. Spatial averaging of model pressure signatures acquired over a range of longitudinal positions reduced the effects of tunnel flow distortions and the interference of the rail flow field and shocks on the model pressure signatures. The test was run at approximate Mach numbers of 1.36, 1.4, and 1.47, and the model was set at various angles of attack and roll relative to the rail. Plots of the model signatures for representative variations of Mach number, model angles, control deflections, and height relative to the rail are provided throughout the report. Repeatability was generally very good and gave confidence in the quality of the measurements. The signatures measured at various heights from the rail provided insight into the aging of the model shocks as they propagated from 1.2 to 3 body lengths from the model. Off-track signatures up to 45° from centerline obtained by rolling the model gave indications of the shock flow fields across the width of the sonic boom carpet. The deflections of the various control surfaces allowed assessment of the boom sensitivity to the control surface movements.

Sonic boom↗

NASA NTRSDate not supplied

TechEdSat 7, 10, 13, 15: Exo-brake Experiments on the ISS, First Virgin Orbit, and First Firefly-Alpha Test Flights

The TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has been studying cube satellite re-entry technologies with a focus on Exo-Brake drag device research. An exo-atmospheric braking device, the Exo-Brake uses the tenuous upper atmosphere acting in a free molecular flow regime to enable controllable adjustment of the drag profile of the host spacecraft, currently enabling rapid disposal of small spacecraft after mission conclusion, and eventual targeted de-orbit to a desired entry point at the Von Karman line, or approximately 100km in altitude. The TES-7 mission, flown on the first successful Virgin Orbit flight January 17, 2021, was injected into a 500km, 61-degree inclination orbit, with an expected orbital lifetime of approximately ten years. After successful deployment of a unique hydrogen gas-cell inflation design ‘disposal’-type Mylar Exo-Brake intended to rapidly de-orbit the spacecraft, the maximum expected orbital lifetime of the TES-7 spacecraft was successfully reduced from ten years to 1.3 years, an 87% reduction in orbit lifetime via a passive, fuel-less system. The subsequent TES-13 mission utilized a new, less complex ‘disposal’-type Exo-Brake design made from collapsible rigid struts rather than inflated struts to reduce the engineering, construction, and safety complexities introduced by the prior hydrogen gas inflation design. The rigid strut Exo-Brake design is stowed via rotational compression and deploys using only stored spring energy once released via electronic actuator. This new rotation compression storage design has become the new Exo-Brake design standard used on TES missions thanks to its simplicity. Following on the success of this new Exo-Brake design demonstrated by TES-13, the design was further refined to enabled active manipulation of the Exo-Brake effective drag area though a winch-like system. Both the TES-10 and TES-15 spacecraft were equipped with geometrically similar Exo-Brake devices capable of such active drag modulation, with the intent of studying the operational impact of having such devices on cube satellite missions. To increase the survival time of the Exo-Brake at low altitudes and thus gain more experiment time and better guidance capability, TES-15 was equipped with a modulated Exo-Brake constructed from 3M™ Nextel™ 440 ceramic oxide fiber, the same fabric material used in the Space Shuttle TPS system, rather than Mylar. After launching on Alpha Flight 2 October 1st, 2022, Firefly’s first successful launch, TES-15 met the same modulation restrictions as TES-10, with modulation prohibited above 200km to avoid possible collision with other spacecraft. In this case, a low deployment orbit caused an extremely short mission life, which, coupled with delayed spacecraft identification, exacerbated collision concerns and caused performance data of the high-temperature Exo-Brake design to be inconclusive. As such, the Nano Orbital Workshop has taken a new approach of only conducting modulated Exo-Brake research on missions deploying below ISS altitude to avoid collision avoidance restrictions, and is working to improve spacecraft identification and location reporting techniques to increase experiment durations. Upcoming TES mission will therefore use one of two classes of Exo-Brake depending on their target altitude, as to be described in the submission.

Marcus Murbach↗

NASA NTRSDate not supplied

Simplified Applied Loads of a Transonic Truss-Braced Wing Derived from Computational Fluid Dynamics

The transonic truss-braced wing (TTBW) concept is under consideration by the NASA Advanced Air Transport Technology (AATT) project due to its potential to reduce fuel consumption of transport aircraft. To properly evaluate the TTBW concept, detailed structural modeling and subsequent test planning is underway, which requires a simplified set of discrete applied loads that simulate the distributed aerodynamic pressures. Given the unique architecture of the TTBW and its intended operation in the transonic regime, computational fluid dynamics (CFD) is the ideal approach to employ to ensure the aerodynamics of this configuration are sufficiently captured. To convert aerodynamic results into input for structural models, application of a data transfer tool, Discrete Data Transfer Between Dissimilar Meshes (DDTBDM), is presented to resolve aerodynamic pressures from CFD into single load vectors at hardpoints along both the wing and the strut. Evaluation of mapping the aerodynamic forces to hardpoints at rib and spar intersections in a structural model is performed, and the results are also compared with a linear static aeroelastic analysis. The structural responses indicate that distributing forces along only the wing and strut forward spars is insufficient for simulating the distributed aerodynamic loads. Adding moments along the forward spars improved the global response of the wing, but the point moments created unrealistic local rotations within the structure. When distributing loads along both the forward and aft spars of the wing and strut, the global response was less sensitive to the inclusion of point moments, which indicated the arrangement of point forces alone was sufficient input for structural design work and testing and provided a more continuous loading profile.

Finite Element↗

NASA NTRSDate not supplied

Simplified Applied Loads of a Transonic Truss-Braced Wing Derived from Computational Fluid Dynamic

Finite Element↗

NASA NTRS2024

Structural Characterization of a TriTruss Module

The TriTruss is a novel structural module developed by researchers at NASA Langley Research Center (LaRC) that can be used in space to assemble large support structures for a variety of applications. One such application is the metering truss or primary mirror backbone support structure of an In-Space Assembled Telescope (iSAT). For the iSAT application, the TriTruss will be supporting mirror segments, payloads, and instruments, all of which require the TriTruss to have a high stiffness. Structural characterization from testing and analysis is needed to ensure the integrity of the struts that make up a TriTruss module is maintained when subjected to loads representative of the application. The test setup and loads applied to the TriTruss module as well as the analytical methods used to predict the response of the structure under conditions representative of those implemented during testing will be discussed. Also, the results obtained from testing and analysis will be summarized. The goal for the characterization study was to achieve a correlation within 10% between the test data and the analysis. Overall, the correlation varied for the struts with a few struts still having a larger error margin after further studies were conducted to improve the correlation through additional analysis.

Characterization↗

NASA NTRS2024

Scalability in SLA lattice through lattice orientation and hybrid frame and plate architectures

Lightweighting has been a key goal for engineers and designers, with lattice structures widely explored as the building blocks for structural components. Cellular structure-inspired lattice truss frame designs made of struts, have been extensively studied. All plate-based lattice designs have superior mechanical performance. Limits in scalability occur from formation of closed pockets limiting uv curing in processes like stereolithography (SLA). We examine hybrid frame and plate body-centered cubic-simply cubic (BCC-SC) lattices under compression. Unit cells and scaled up lattice exhibit an increase in yield stress and modulus with the addition of plates. The loading direction on the hybrid frame and plate unit cells affected the magnitude of improvement. Simulations and measurements indicated that the optimal lightweight lattice was determined to be when two plates were placed opposite each other with plates buttressing the struts, inhibiting buckling of the struts aligned with the loading direction. This lattice resulted in 63% improvement in specific modulus, a 137% improvement in specific yield point, and a 360% improvement in specific energy absorption (SEA) and the scaled up 4 × 4 × 4 scaled-up structures, showed a 107%, 148%, and 297% in specific modulus, specific yield point, and SEA, respectively A combined stretching-bending behavior was identified in optimal orientations reflecting the delayed buckling mechanism paired to a rising stress-strain curve past the elastic yield indicating bending resistance. The mass moment of inertia was found to be a key parameter correlating optimum orientation for the same number of plates added to the BCC-SC frame.

Mahan Ghosh↗

DOE OSTI2024

Test capsules for measuring a change in at least one property of a material, and related methods

A test capsule for measuring at least one property of a material exposed to nuclear radiation comprises a lattice structure configured to exhibit a change in at least one property responsive to exposure to nuclear radiation. The lattice structure comprises a first strut and a second strut connected to the first strut at a node. Related test capsules and methods are also described.

Roach, Robert A.↗

DOE OSTI2026

Microstructure‐Informed Analysis Framework for Lattice Structures: Guiding Topology‐Material Synergy in Titanium Alloys

In this work we discuss a microstructure‐informed analysis framework for lattice structures that maps the material's microstructural response to guide topology selection and mechanical performance optimization. By coupling geometrical topology with intrinsic material behavior, we demonstrate how anisotropic microstructural response can inform the design of optimized lattice structures. To illustrate this concept, we focus on two distinct classes of titanium alloys: Ti5553 (Ti‐5Al‐5Mo‐5V‐3Cr wt%), which exhibits a predominantly ‐phase microstructure, and Ti64 (Ti‐6Al‐4V wt%), which features a dual‐phase structure. These alloys exhibit markedly different mechanical responses under multiaxial loading in “fully dense” solid form. The strut‐level stress analysis of these alloys reveals how specific microstructural characteristics can guide the selection of appropriate lattice topologies. Two representative lattice configurations, one stretching‐dominated and one bending‐dominated, are evaluated under identical loading conditions to explore how microstructure‐driven design can lead to topology choices that are better suited to accommodate shear or other critical local stress states, thereby enhancing mechanical performance. A strut‐level mechanics‐based analysis is performed to evaluate shear stress distribution and highlight the role of topology‐microstructure synergy and compatibility in determining overall lattice behavior. The findings emphasize the importance of designing structures that are both load‐aware and microstructure‐responsive, enabling more effective material utilization in advanced engineering applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Influences of shock imprinting on mix in a 3D-printed porous media

Mixing of materials in porous media can cause a significant impact on fusion yield as previously demonstrated by the National Ignition Facility (NIF) MARBLE Campaign. Initially, the reactants are separated, with deuterium in the lattice struts and a tritium gas fill in the voids. Lattice parameters such as the strut thickness and relative pitch, provide a control for the mix parameters in the experiment. Los Alamos National Laboratory’s (LANL) BOSQUE project looks to better understand how the mix of the reactants and shell materials impact the fusion burn and resultant yield on various laser platforms. xRAGE’s Eulerian hydrodynamics and adaptive mesh refinement (AMR) provide the unique ability to study the impacts of multiscale features of complex lattice structures. This modeling provides the ability to measure shock front variations as the wave progress’ through a given media. Initial conditions of the lattice are essential to accurately model mix and burn measured by experiment. By varying the initial orientation and densities of these lattice regions the early time dynamics of how the shock is launched into the system is changed and advocates for the study of resulting effects. In this work, we will study the sensitivities of shock effects in varying 3D printed geometric systems and how these shocks alter the structure and mix in the lattice. We will discuss both preliminary experimental results and simulations to help plan and constrain future experiments where we will study the impact of different lattice geometries and lattice bulk densities. This work concludes with the relative impacts of lattice geometries on shock speeds at different bulk densities and the resultant mix widths due to those shock interactions. We see agreement with theory at the higher end of our bulk density study, however, as we approach lower bulk density systems the dynamics of these interactions begin to change.

2 Photon Polymerization↗

DOE OSTI2026

Local convection characteristics of inline arrangement of Kagome-shaped unit cells in a square duct

Transient liquid crystal thermography experiments have been conducted to determine detailed convective heat transfer coefficients at the endwalls of lattice-frame configurations based on Kagome-shaped unit cells. Kagome unit cells with porosity of 0.88 were arranged in an inline manner, where two such arrangements were studied. In the first arrangement, a total of ten unit cells were placed next to each other along the streamwise direction resulting in a continuous configuration. In the 2nd arrangement, alternate unit cells from the continuous configuration were dropped, resulting in a discrete configuration which featured a total of 5 Kagome unit cells. Due to the asymmetric nature of the strut connections within the unit cell, the convective heat transfer coefficient maps were determined for the two opposite walls where the struts meet the endwalls. Transient liquid crystal experiments were conducted for Reynolds number ranging between 10,000 and 30,000. Here, the study was focused on the developing nature of flow along the streamwise direction and the local convection characteristics for continuous and discrete arrangement of unit cells. For the continuous configuration, the Nusselt number ratios (N u /Nu 0 ) varied between 3.15–3.46 and 2.75–2.89 for the two walls A and B, respectively. For the discrete configuration, convective heat transfer coefficients varied between 2.56–2.71 and 2.09–2.40 for the two walls. Kagome unit cells have the potential to be fabricated through inexpensive manufacturing routes such as wire-woven method and these unit cells find their applications in the areas which require different heat transfer levels on opposite walls.

Kagome↗

DOE OSTI2025

Demonstration of new MeV-scale capabilities in large neutrino LArTPCs using ambient radiogenic and cosmogenic activity in MicroBooNE

Large neutrino liquid argon time projection chamber (LArTPC) experiments can broaden their physics reach by reconstructing and interpreting MeV-scale energy depositions, or blips, present in their data. We demonstrate new calorimetric and particle discrimination capabilities at the MeV energy scale using reconstructed blips in data from the MicroBooNE LArTPC at Fermilab. We observe a concentration of low-energy (<3 MeV) blips around fiberglass mechanical support struts along the time projection chamber edges with energy spectrum features consistent with the Compton edge of 2.614 MeV 208 Tl decay 𝛾 rays. These features are used to verify proper calibration of electron energy scales in MicroBooNE’s data to few percent precision and to measure the specific activity of 208 Tl in the fiberglass composing these struts, (11.7 ± 0.2⁢(stat) ± 3.1⁢(syst)) Bq/kg. Cosmogenically produced blips above 3 MeV in reconstructed energy are used to showcase the ability of large LArTPCs to distinguish between low-energy proton and electron energy depositions. An enriched sample of low-energy protons selected using this new particle discrimination technique is found to be smaller in data than in dedicated corsika cosmic-ray simulations, suggesting either incorrect corsika modeling of incident cosmic fluxes or particle transport modeling issues in geant4.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Evaluation of Composite Structural Materials for Heliostat Cost Reduction

Structures manufactured from steel comprise up to 40% of a CSP heliostat's cost. Composite structures represent a potential opportunity to reduce this cost. A reference heliostat structural model has been created with a reflector area of 25m 2 . The design, constructed of low-carbon steel, pro-vides baseline deflection and stiffness under a 21 m/s operating wind speeds. Wind loads on the tracker structure are determined for both operating and stow conditions. An established roster of suitable metal alternative materials is considered including: glass, basalt, and carbon reinforced polymer (GFRP, BFRP, and CFRP respectively). Three heliostat components are investigated: the pylon, torque tube, and the purlin-strut assembly. Composite material properties are substituted for those of steel, and the beams are re-sized to match the original steel components' deflection under given wind loads. Weight and cost changes resulting from this resizing are evaluated. It is found that GFRP and BFRP represent a 3X–6X cost premium for the same operating deflection character-istics as steel across all three investigated component classes; with weight reduction only achieved for the purlin-strut assembly. While CFRP components can achieve approximately 25–75% weight savings depending on the application, this comes with a 9X–14X cost increase over the steel base-line for tube-type structures and roughly 5X cost increase when replacing c-channel structures. This work does not rule out the possibility of cost savings when the heliostat design and kinematics to take advantage of composites' specific properties.

14 SOLAR ENERGY↗

DOE OSTI2025

Additive Manufacturing of Lattice Structures for Catalyst Applications

Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Hypersonic wake velocity measurements using acetone molecular tagging velocimetry

Molecular tagging velocimetry, a minimally intrusive laser diagnostic, was used to find quantitative off-body velocity measurements in the wake of both strut-mounted and free-flight spheres in hypersonic flow. Acetone gas seeded in the flow was excited using the fourth harmonic of a pulse-burst Nd:YAG laser. The experimental tests were validated and compared to simulations using a continuous Galerkin flow solver and an adaptive mesh refinement process. Near the centerline in the wake of the sphere, velocities between −105 and 65 m/s were observed due to reverse flow in the viscous shear layer. Similarly, the simulated data showed negative velocity values in the shear layer region. Outside of the shear layer, average velocities of 730 m/s were observed in both the experimental and simulated results. The overall average uncertainty for the strut-mounted and free-flight cases was estimated to have an accuracy of ±4% (±35.5m/s or 4.9%). In conclusion, this non-intrusive technique provides a velocity map of the wake behind a sphere under hypersonic conditions.

42 ENGINEERING↗

DOE OSTI2025

Additive Manufacturing of Lattice Structures for Catalyst Applications

Ghanadi, Nahal [Oregon State University] (ORCID:00↗

DOE OSTI2024

New MeV-Scale Capabilities in Large Neutrino LArTPCs Using Ambient Radiogenic and Cosmogenic Activity in MicroBooNE

Large neutrino liquid argon time projection chamber (LArTPC) experiments can broaden their physics reach by reconstructing and interpreting MeV-scale energy depositions present in their data. We use data from MicroBooNE, an 85 tonnes LArTPC exposed to Fermilab neutrino beams from 2015 until 2021, to demonstrate new calorimetric and particle discrimination capabilities for isolated $\sim \mathrm{O}(1 \mathrm{MeV})$ energy depositions referred to as blips. We observe a concentration of low energy ( $<3$ MeV ) blips around fiberglass mechanical support struts along the TPC edges with energy spectrum features consistent with the Compton edge of 2.614 MeV Tl-208 decay gamma rays. These features are used to verify proper calibration of electron energy scales in MicroBooNE's data to few percent precision and to measure the specific activity of Tl-208 in the fiberglass composing these struts. Cosmogenicallyproduced blips above 3 MeV in reconstructed energy are used to showcase the ability of large LArTPCs to distinguish between low-energy proton and electron energy depositions.

Andrade Aldana, Diego Armando↗

DOE OSTI2024

Performance of a Prototype Heliostat Having a Twisting Mechanism to Maintain Focus Throughout the Day

A prototype heliostat has been designed and built with a rectangular reflector whose shape is altered automatically through the day, to maximize concentration at the receiver. The shape changes needed to form solar disc images, which give the highest possible concentration, can be realized by twisting the reflector from its corners, provided that a target-oriented, dual-axis mount is used. Then a cam mechanism connected to the second (cross) axis drive, turning with the angle of incident sunlight, may be used to twist the reflector as needed. Our prototype reflector comprises a single glass mirror, 2.4 m x 3.3 m, attached to a steel frame. Four diagonal back struts extend from the central mechanism out to the rectangular frame corners. The glass mirror of the prototype is attached to the steel frame by 58 screw actuators. Before twisting the frame, the glass shape is adjusted to the biconic shape needed to form a 1 m diameter disc image on a 113 m distant target when sunlight is incident at 60°. To form disc images over the full range of angles of incidence from 0° (normal incidence) to 70°, the struts push the corners up and down by up to 17 mm. A reflectometry metrology system has been used to set the 58 adjustment screws for the initial shape to an accuracy of ≤ 0.6 mrad, and to measure the accuracy of the different twisted shapes. The prototype will be tested at NSTTF early next year.

14 SOLAR ENERGY↗

NASA NTRS1964

Characteristics of a Lunar Landing Configuration Having Various Multiple-Leg Landing-Gear Arrangements

An experimental investigation has been made of some lunar-landing characteristics of a 1/6-scale dynamic model of a landing module having multiple-leg landing-gear systems. Symmetric four-point and five-point systems were investigated. The landing-gear legs were inverted tripod arrangements having a telescoping main strut which incorporated a yielding-metal strap for energy dissipation, hinged V-struts, and circular pads. The landing tests were made by launching a free model onto an impenetrable hard surface (concrete) and onto a powdered-pumice overlay of various depths. Landing motion and acceleration data were obtained for a range of touchdown speeds, touchdown attitudes, and landing-surface conditions. Maximum normal acceleration experienced at the module center of gravity during landings on hard surface or pumice was 2g (full-scale lunar value in terms of earth's gravity) over a wide range of touchdown conditions. acceleration experienced was 12 1/2 radians/sec(exp 2) and maximum longitudinal acceleration was 1 3/4g. The module was very stable with all gear configurations during landings on hard surface (coefficient of friction, micron = 0.4) at all conditions tested. Some overturn instability occurred during landings on powdered pumice (micron = 0.7 to 1.0) depending upon flight path, pitch and yaw attitude, depth of pumice, surface topography, and landing-gear configuration. The effect on stability of roll attitude for the limited amount of roll-attitude landing data obtained was insignificant. Compared with the four-point landing gear, the five-point system with equal maximum gear radius increased landing stability slightly and improved the static stability for subsequent lunar launch. A considerable increase in landing stability in the direction of motion was obtained with an asymmetric four-point gear having two pads offset to increase gear radius by 33 percent in the direction of horizontal flight.

Blanchard, Ulysse J.↗