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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 325 records · Page 18

Life Cycle Inventories and Data Gap Analysis for Rare Earth Elements: Neodymium and Dysprosium from Mining to Magnets

The United States demand for Neodymium-Iron-Boron (NdFeB) magnets, produced from rare earth elements (REEs) such as (Nd) and Dysprosium (Dy), far exceeds its nascent domestic production capacity, rendering it reliant on vulnerable global supply chains dominated by China. To guide research and development investments in securing U.S. REE supply, defensible benchmark metrics across environmental, economic, and social dimensions are needed. In this study, we built globally-representative, process-based cradle-to-cradle life cycle inventories for Nd and Dy in NdFeB magnets lifecycles, encompassing primary material acquisition, beneficiation, smelting and refining, metal processing, specialty alloy and chemical transformation, subcomponent manufacturing, consumer application (use phase) and end-of-life management. We carried out detailed literature review, and applied process engineering principles to build industry-representative upscaled life cycle inventories for both metals. We used these models to conduct bottom-up literature review and gap analysis on existing literature, compilation of data sources for each life cycle stage (and transformations where necessary), and a preliminary technoeconomic analysis (TEA)/life cycle costing analysis (LCCA). Findings from this work emphasize the need for metal specific, representative REE LCIs to establish robust benchmarks for advancing sustainable REE technologies and guiding R&D in REE supply chains.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Hydrocracking Plastic Mixtures into Xylene

Our research aims to tackle the challenge in recycling end-of-life plastics, the accumulation of which has become a grand challenge to our society, sustainability and economy. Guided by life-cycle assessment (LCA) and tech-economic analysis (TEA), we specifically target the catalytic conversion of low-cost #3-7 plastic mixtures ($\$$5/ton) into p-xylene (>$\$$1000/ton), one of the most valuable hydrocarbon products. This goal is achieved by carrying out integrated research including catalysis, process engineering, and reactor design. The ultimate goal of this project is to enable energy-efficient and economically viable depolymerization of end-of-life plastic mixtures into value-added commodity chemicals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

EMSL Community Science Campaign Meeting: Critical Minerals and Materials - Rhizo Critical Campaign Breakout Session Report Summary

The “Critical Minerals Biogeochemistry in the Rhizosphere – Ultramafic Soils (Rhizo Critical)” campaign breakout (BO) session was organized to identify major knowledge gaps and fundamental research needs in rhizosphere microbiology and geochemistry that, if addressed, could transform our ability to recover critical minerals from ultramafic soil systems. We sought to identify significant challenges that must be surmounted in the pursuit of deeper science knowledge. Our ultimate goal is to understand this landscape well enough to identify and prioritize opportunities for EMSL to make the greatest impact with Environmental Transformations and Interactions (ETI) science area research campaigns focused on the biogeochemical processes controlling the behavior of critical minerals and materials in the rhizosphere. The increasing demand for critical materials and minerals (CMM) in the U.S. has heightened interest in low-grade ores with much attention on ultramafic soils, which contain valuable metals such as nickel (Ni), chromium (Cr), manganese, cobalt (Co), and copper (Lee et al., 2025; DOE CMM Report, 2023) used in advanced battery, magnet, wiring and wind turbines, and stainless steel technologies. Metal hyperaccumulating plants grown in ultramafic soils can extract economically valuable concentrations of CMMs through the process of phytomining. This technology has evolved from phytoremediation, which involves using plants to cleanse contaminated environments by removing, detoxifying, or stabilizing pollutants like metals and organic compounds. Hyperaccumulator plants are capable of storing metals in their living tissues at concentrations hundreds to thousands of times higher than those found in 'normal' plants. For instance, while the average concentration of Ni in the dry matter of plants growing in typical soils is usually less than 5 µg g?¹, Ni hyperaccumulation is defined by concentrations exceeding 1,000 µg g?¹ (Corzo Remigio et al., 2020; Reeves et al., 2018). Phytomining research has primarily focused on Ni (Rylott and van der Ent, 2025), for which the U.S. has very limited conventional mines in operation. Most soils typically contain Ni concentrations ranging from 7 to 50 mg kg-1, whereas serpentine soils exhibit significantly higher levels, with Ni content often ranging between 700 and 8,000 mg kg-1 (Sobczyk et al., 2017). While more than 500 plant species in over 50 different families have been identified as Ni hyperaccumulators (Kidd et al., 2018), Ni phytomining (and phytominng in general) remains largely untested because most studies are short-term, small-scale, and conducted under simplified or artificially enriched conditions, so they fail to capture the low metal concentrations, environmental variability, and management constraints that would be needed for a field-scale demonstration. Few hyperaccumulator species have been validated as true “metal crops,” and their biomass production, stress tolerance, and rooting characteristics are usually too poor to yield economically meaningful metal outputs. Critically, the basic mechanisms of metal uptake, transport, and sequestration, especially as shaped by belowground processes such as root exudation, rhizosphere chemistry, and root–microbe interactions that control metal mobility and bioavailability (Montreemuk et al., 2023; Kidd et al., 2018; Durand et al., 2023; Alford et al., 2010), are still only partially understood, and downstream metal recovery from biomass is rarely optimized. Because these limitations stem from gaps in fundamental knowledge rather than from a failure of the concept itself (Rylott and van der Ent, 2025; van der Ent et al., 2015), there is a strong need for basic science that dissects plant metal homeostasis, rhizosphere and microbial processes, and their integration with soil chemistry and process engineering to design more robust, scalable phytomining systems.

Ahkami, Amirhossein↗

Topological Control of Triply Periodic Minimal Surfaces for Thermal Design and Advanced Manufacturing: A Gyroid Case Study

Recently, there has been a heightened interest in using triply periodic minimal surfaces (TPMSs) in the design of compact process engineering components. The benefits of high surface area per unit volume, modular form, and inherent periodicity provide a holistic self-supporting network and flow-conducive features. Applications of importance include thermal power management, biomimetic scaffolds and structures, and feasibility of advanced manufacturing. This study presents a novel approach to the manipulation of the characteristic Schwarz-G, or gyroid TPMS, for thermal design in the context of advanced manufacturing. The study presents relationships between design parameters and resulting surface area as a target response using the characteristic equation of a gyroid. Through parametric control, the characteristic equation is manipulated to produce a 20-fold increase in achievable area over a baseline design characteristic of 25.4 mm through controlled combinations of design parameters. A second relationship is presented as a function of the maximum area achieved and manipulated design parameters. Through the analysis, the study presents a framework to identify and maximize the achievable area of TPMSs for advanced manufacturing and thermal management applications.

gyroid↗

Modified contour projector makes excellent contour densitometer

Thin glass beam splitter, densitometer head, and densitometer electronics are incorporated in a standard contour projector. The density contour of small areas of photographic film can be read. This instrument can be used as a research tool in process engineering.

Exton, R. J.↗

Quality - Inexpensive if a way of life.

NASA major projects require phased planning. The participation of persons charged with maintaining the proper quality during the last two of four phases has become accepted practice. Current objectives are concerned with the application of quality assurance techniques during the second phase. It is pointed out that quality must be emphasized during the entire engineering process, starting with the selection of the components.

Grau, D.↗

Refractory inserts used to form cooling passages in cast superalloy turbine vanes

Economical technique has been developed for manufacturing air-cooled turbine blades and vanes for gas turbine engines. Process uses tungsten inserts to form coolant passages. After casting, inserts are reduced to tungsten oxide during sublimation with oxygen at elevated temperature. Tungsten oxide is leached out of coolant passages with a molten salt solution.

Terpay, A.↗

MSFC Skylab instrumentation and communication system mission evaluation

An evaluation of the in-orbit performance of the instrumentation and communications systems installed on Skylab is presented. Performance is compared with functional requirements and the fidelity of communications. In-orbit performance includes processing engineering, scientific, experiment, and biomedical data, implementing ground-generated commands, audio and video communication, generating rendezvous ranging information, and radio frequency transmission and reception. A history of the system evolution based on the functional requirements and a physical description of the launch configuration is included. The report affirms that the instrumentation and communication system satisfied all imposed requirements.

Adair, B. M.↗

Automated process planning system

Program helps process engineers set up manufacturing plans for machined parts. System allows one to develop and store library of similar parts characteristics, as related to particular facility. Information is then used in interactive system to help develop manufacturing plans that meet required standards.

Mann, W.↗

HiMAT onboard flight computer system architecture and qualification

Two highly maneuverable aircraft technology (HiMAT) remotely piloted research vehicles (RPRV's) are being flight tested at NASA Dryden Flight Research Center, Edwards, California, to demonstrate and evaluate a number of technological advances applicable to future fighter aircraft. Closed-loop primary flight control is performed from a ground-based cockpit utilizing a digital computer and up/down telemetry links. A backup flight control system for emergency operation resides in one of two onboard computers. Other functions of the onboard computer system are uplink processing, downlink processing, engine control, failure detection, and redundancy management. This paper describes the architecture, functions, and flight qualification of the HiMAT onboard flight computer systems.

Myers, A. F.↗

D-1 report: The first German spacelab mission

Introduction of a new popular magazine on the DI mission, the first West German Space mission. The DI project office publishes the magazine. The German sponsored astronauts are to study the gravitational effects of reduced gravity on the human generated processes of the environment. Other areas of concern are boundary surface and transport phenomena, physical chemisty and process engineering, metals and composite materials, and single crystals.

Source record↗

Summary results of the Industry Conference on the Commercial Use of Space

The future intentions of the Federal Republic of Germany in the area of the commercialization of space are presented. It is shown that significant advances in microgravity research, particulary in the areas of materials science, composite materials, physical chemistry, crystal growth, biology, and process engineering will have an effect on future plans for establishing sponsoring organizations to guide commercial interests in German space research. An organizational and functional outline of a proposed sponsoring organization to promote space commercialization under German supervision, including the objectives, the target group to be served, and the administrative structure, is presented. The role of the DFVLR (German Aerospace Research Establishment) and the BMFT (German Ministry for Research and Technology) as sponsoring organizations representing the interests of the German government is shown.

REUSE↗

Planning the Voyager spacecraft's mission to Uranus

The application of the systems engineering process to the planning of the Voyager spacecraft mission is described. The Mission Planning Office prepared guidelines that controlled the use of the project and multimission resources and spacecraft consumables in order to obtain valuable scientific data at an acceptable risk level. Examples of mission planning which are concerned with the design of the Deep Space Network antenna, the uplink window for transmitting computer command subsystem loads, and the contingency and risk assessment functions are presented.

Plagemann, Stephen H.↗

A systems engineering approach to automated failure cause diagnosis in space power systems

Automatic failure-cause diagnosis is a key element in autonomous operation of space power systems such as Space Station's. A rule-based diagnostic system has been developed for determining the cause of degraded performance. The knowledge required for such diagnosis is elicited from the system engineering process by using traditional failure analysis techniques. Symptoms, failures, causes, and detector information are represented with structured data; and diagnostic procedural knowledge is represented with rules. Detected symptoms instantiate failure modes and possible causes consistent with currently held beliefs about the likelihood of the cause. A diagnosis concludes with an explanation of the observed symptoms in terms of a chain of possible causes and subcauses.

Dolce, James L.↗

Space station functional relationships analysis

A systems engineering process is developed to assist Space Station designers to understand the underlying operational system of the facility so that it can be physically arranged and configured to support crew productivity. The study analyzes the operational system proposed for the Space Station in terms of mission functions, crew activities, and functional relationships in order to develop a quantitative model for evaluation of interior layouts, configuration, and traffic analysis for any Station configuration. Development of the model involved identification of crew functions, required support equipment, criteria of assessing functional relationships, and tools for analyzing functional relationship matrices, as well as analyses of crew transition frequency, sequential dependencies, support equipment requirements, potential for noise interference, need for privacy, and overall compatability of functions. The model can be used for analyzing crew functions for the Initial Operating Capability of the Station and for detecting relationships among these functions. Note: This process (FRA) was used during Phase B design studies to test optional layouts of the Space Station habitat module. The process is now being automated as a computer model for use in layout testing of the Space Station laboratory modules during Phase C.

Tullis, Thomas S.↗

Integrating automated support for a software management cycle into the TAME system

Software managers are interested in the quantitative management of software quality, cost and progress. An integrated software management methodology, which can be applied throughout the software life cycle for any number purposes, is required. The TAME (Tailoring A Measurement Environment) methodology is based on the improvement paradigm and the goal/question/metric (GQM) paradigm. This methodology helps generate a software engineering process and measurement environment based on the project characteristics. The SQMAR (software quality measurement and assurance technology) is a software quality metric system and methodology applied to the development processes. It is based on the feed forward control principle. Quality target setting is carried out before the plan-do-check-action activities are performed. These methodologies are integrated to realize goal oriented measurement, process control and visual management. A metric setting procedure based on the GQM paradigm, a management system called the software management cycle (SMC), and its application to a case study based on NASA/SEL data are discussed. The expected effects of SMC are quality improvement, managerial cost reduction, accumulation and reuse of experience, and a highly visual management reporting system.

Sunazuka, Toshihiko↗