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DOE OSTI2026

Recycling of Printed Circuit Boards to Recover Critical Materials

The printed circuit board (PCB), a central component of most electronic devices, represents a significant fraction of the electronic product waste stream. The complex composition of PCBs, consisting of metals, polymers, and fiberglass, requires specialized recovery steps to reclaim valuable and critical materials and the safe disposal of brominated compounds. In this review paper, we describe the current state of critical material recovery and traditional recycling technologies and identify key obstacles to large-scale implementation. Metals present at high concentrations, such as copper, lead, and iron, are conventionally recovered from PCBs using hydrometallurgical, pyrometallurgical, or electrometallurgical processes. Hydrometallurgical methods achieve high selectivity through chemical leaching but pose significant challenges for effluent and reagent recovery. Pyrometallurgical methods facilitate rapid metal separation through smelting but require substantial energy and may release harmful gases. Electrometallurgical techniques produce high-purity metals but are constrained by pretreatment requirements and the consumption of energy. The non-metallic fraction of PCB waste is recycled using thermochemical conversion, microwave-aided heating, and direct recycling of epoxy–fiberglass composites, enabling material or energy recovery. The recovered polymer from direct recycling may have reduced mechanical strength and poor compatibility with new polymer matrices, and the resulting products from the thermal conversion suffer from incomplete conversion, degradation of quality, and residual contamination, as compared to synthetic polymers. Recent process developments have focused on extracting rare earth and supply-critical materials present at lower concentrations in the waste stream. The literature on existing and emerging approaches for recycling PCB wastes is reviewed to identify sustainable, economically viable, and environmentally responsible strategies for the recovery and reuse of critical materials from waste streams.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Modified US Army U-8F ground vibration test

The Dryden Flight Research Facility of NASA Ames Research Center conducted a ground vibration test on a modified U.S. Army U-8F airplane. Modifications included new engines, propellers, and engine-mounted truss assemblies. The ground vibration test was conducted using sine dwell, single-point random, and impact excitations. The test was performed to determine modal frequencies, mode shapes, and structural damping coefficients of the airframe and propeller with full and empty fuel tanks. The data presented include frequency response plots, rigid-body and structural modal frequencies, and mode shapes.

Kehoe, M. W.↗

NASA NTRS1986

Installation aerodynamics of wing-mounted, single-rotation propfans

The installation of advanced (M = 0.8) turboprop propulsion systems on transport aircraft represents a challenging task to design engineers. The installation aerodynamics of wing-mounted, single-rotation, tractor turboprop systems have been extensively investigated by NASA Ames using a large powered semispan wind tunnel model. Two configurations have been studied: a straight under-the-wing (UTW) nacelle and a contoured over-the-wing (OTW) configuration. The installation characteristics of these two configurations are presented in terms of installed drag, wing pressure distributions, and surface oil flows. Through the use of wing leading-edge modifications, the installed drag of the UTW nacelle was reduced to less than isolated nacelle drag at the cruise condition of M = 0.8 with a wing C(L) of 0.5. At this condition, the favorable interference is attributed to the recovery of a portion of the swirl in the slipstream generated by the single rotation propeller. The OTW installation represented a much more difficult task. For the configuration tested, the installed drag was unacceptably high and demonstrated the sensitive nature of installing a nacelle/slipstream combination in the transonic flow regime.

Bencze, Daniel P.↗

NASA NTRS1992

Determination of YAV-8B Reaction Control System bleed flow usage

Using a calibrated Rolls-Royce Pegasus engine, total Reaction Control System (RCS) bleed flow rates have been measured on a YAV-8B Harrier during typical short takeoff, transition, hover and vertical landing maneuvers. Using existing aircraft instrumentation and pressure taps located in the RCS ducts, bleed flow rates at each RCS valve were also measured directly during flight and ground tests. These data were compared with the calibrated engine data and with the RCS part of a YAV-8B mathematical model used in piloted simulation at NASA Ames Research Center. Areas of disagreement were small, being confined to the estimation of closed RCS valve leakages and the modeling of the RCS butterfly valve pressure losses.

Borchers, Paul F.↗

NASA NTRS1994

Preliminary test results from the CELSS Test Facility Engineering Development Unit

As part of the NASA Controlled Ecological Life Support System (CELSS) Program, a CELSS Test Facility (CTF) is being planned for installation on the Space Station. The CTF will be used to provide data on the productivity and efficiency of a variety of CELSS higher plant crops grown in the microgravity environment of the Space Station. Tight environmental control will be maintained while data on gas exchange rates and biomass accumulation rates are collected. In order to obtain an early realistic determination of the subsystem and system requirements necessary to provide the environmental conditions specified for CTF crop productivity experiments, an Engineering Development Unit (EDU) has been designed, constructed and is in the process of subsystem and system testing at NASA Ames Research Center. The EDU is a ground test-bed which will be used to characterize the integrated performance of major subsystem technologies, to evaluate hardware candidates and control strategies required for the CTF, and to further define the ability to meet CTF requirements within present Space Station constraints. This paper reviews the functional requirements for the EDU, and focuses on the performance evaluation and test results of the various subsystems. Preliminary integrated performance results and control system operation are addressed, and plans for future science and technology testing are discussed.

Kliss, Mark H.↗

NASA NTRS2008

Reaching for the APEX at Ames

The multidimensional design of the APEX program is the result of an extensive research and development effort dating back nearly a decade. "In the late 1990s and early 2000, we were pretty successful at getting new research and technology projects here at the center," Johnson says, "and we had a lack of critical mass of project managers. We were taking people who were primarily researchers and putting them in the position of managing projects." Smith and Johnson held a series of workshops across the center during 2000 and 2001 to gather feedback about how to address this issue. When they briefed the center's senior management on their findings, one of the top recommendations was to establish a project manager development program at Ames. At that point, they cast a wide net for ideas and information. "We did centerwide needs assessment, we did focus groups, we did surveys," Smith says. "We came up with a proposal for what a program would look like, tying in what we knew about the Academy of Program1 Project Leadership (now the Academy for Program/Project and Engineering Leadership, or APPEL), what we've seen at other centers, what other centers have tried. We were always checking to make sure our program mapped to APPEL. We also looked at the PMI [Project Management Institute] model, INCOSE [International Council on Systems Engineering], CMMI [Capability Maturity Model Integration], you name it." "We had a lot of conversations with the Jet Propulsion Lab and Goddard," Johnson adds. "We saw those centers as models for what Ames was aspiring to be in terms of a center for managing space flight missions." Their research confirmed what they already knew-that strong practitioner involvement would be critical to their program design process. 'XPEX is for the practitioner by the practitioner," Smith says. "They have to be a part of designing it. Otherwise there's no way we could design a program that meets their needs." At the same time that they worked at the grassroots level, they also solicited feedback from the center's senior management. "We recognized that in order for anything to succeed here, we needed to have a champion at the center management level," Johnson said. "You have to have champions, and you have to listen to what the senior managers are saying. They have their own ideas." In the case of APEX, one of those ideas fundamentally reshaped the program. "When we originally started, it was a project management development program," Johnson says, "but in our meeting with our center director, he said, 'Project management is important, but we also need to strengthen our systems engineering.' So we basically added that component to the program based on what he wanted."

Kohut, Matthew↗

NASA NTRS1981

Fumigation of Alcohol in a Light Duty Automotive Diesel Engine

A light-duty automotive Diesel engine was fumigated with methanol in amounts up to 35% and 50% of the total fuel energy respectively in order to determine the effect of alcohol fumigation on engine performance at various operating conditons. Engine fuel efficiency, emissions, smoke, and the occurrence of severe knock were the parameters used to evaluate performance. Raw exhaust particulate and its soluble organic extract were screened for biological activity using the Ames Salmonella typhimurium assay. Results are given for a test matrix made up of twelve steady-state operating conditions. For all conditions except the 1/4 rack (light load) condition, modest thermal efficiency gains were noted upon ethanol fumigation. Methanol showed the same increase at 3/4 and full rack (high load) conditions. However, engine roughness or the occurrence of severe knock limited the maximum amount of alcohol that could be fumigated. Brake specific nitrogen oxide concentrations were found to decrease for all ethanol conditions tested. Oxides of nitrogen emissions, on a volume basis, decreased for all alcohol conditions tested. Based on the limited particulate data analyzed, it appears that ethanol fumigation, like methanol fumigation, while lowering the mass of particulated emitted, does enhance the biological activity of that particulate.

Broukhiyan, E. M. H.↗

NASA NTRS1997

An Introduction to Rotorcraft Research at NASA Ames

NASA Ames Research Center, Moffett Field, CA is the NASA lead Center for rotorcraft research. Rotorcraft research at Ames includes system analysis and configuration optimization, aeromechanics, and flight control and cockpit integration. Research in other areas such as composite structure and material, and rotor acoustics are conducted mainly at Langley Research Center, and rotorcraft propulsion and drivetrain are conducted at Lewis Research Center. This seminar will discuss Ames' rotorcraft research goals and some sample research projects and results. The talk will also briefly describe the newly fanned Army/NASA Rotorcraft Division, which combines the resources of rotorcraft branches in NASA Ames Aeronautics Directorate with Army's Aeroflightdynamics Directorate to better achieve the missions of the two previous rotorcraft research organizations at Ames. Rotorcraft research activities at NASA Ames are funded by two main program categories: Research and Technology (RUTH Base program and the Short Haul (Civil Tiltrotor) program. Work in the R&T program is carried out by the research staff in the Army/NASA Rotorcraft Division, and the work on SH(CT) program is carried out jointly by the SH(CT) program office and the Army/NASA Rotorcraft Division. Sample research projects and results in REST base program, such as conceptual assessment of several high-speed rotorcraft, rotorcraft CFD, individual blade control for reduction of external noise and vibration, noise-abatement flight procedures, engine inoperative procedures, handling qualities, and advanced flight control laws are broadly reviewed. High-speed rotorcraft research related to SH(CT) technology development conducted at Ames in the areas of low-noise proprotor, and low-noise terminal-area operations is also discussed.

Chen, Robert T. N.↗

NASA NTRS1985

Workshop on Advances in NASA-Relevant, Minimally Invasive Instrumentation

The purpose of this meeting is to highlight those advances in instrumentation and methodology that can be applied to the medical problems that will be encountered as the duration of manned space missions is extended. Information on work that is presently being done by NASA as well as other approaches in which NASA is not participating will be exchanged. The NASA-sponsored efforts that will be discussed are part of the overall Space Medicine Program that has been undertaken by NASA to address the medical problems of manned spaceflight. These problems include those that have been observed in the past as well as those which are anticipated as missions become longer, traverse different orbits, or are in any way different. This conference is arranged in order to address the types of instrumentation that might be used in several major medical problem areas. Instrumentation that will help in the cardiovascular, musculoskeletal, and psychological areas, among others will be presented. Interest lies in identifying instrumentation which will help in learning more about ourselves through experiments performed directly on humans. Great emphasis is placed on non-invasive approaches, although every substantial program basic to animal research will be needed in the foreseeable future. Space Medicine is a rather small affair in what is primarily an engineering organization. Space Medicine is conducted throughout NASA by a very small skeleton staff at the headquarters office in Washington and by our various field centers. These centers include the Johnson Space Center in Houston, Texas, the Ames Research Center in Moffett Field, California, the Jet Propulsion Laboratory in Pasadena, California, the Kennedy Space Center in Florida, and the Langley Research Center in Hampton, Virginia. Throughout these various centers, work is conducted in-house by NASA's own staff scientists, physicians, and engineers. In addition, various universities, industries, and other government laboratories perform research that cannot be effectively carried out in-house. At the moment, approximately 50% of the work is performed in-house and 50% is extramural. The area of bioinstrumentation pervades every one of our problem areas. In each, equipment or procedures are being developed that will allow more clinical work to be done in a ground-based or spacecraft setting. Although work of this kind goes on throughout the NASA organization and through its grants and contracts in the community at large, the major thrust of it is concentrated at the Jet Propulsion Laboratory which plays a lead role in this type of research and acts as the lead center in bioinstrumentation for NASA. It is recognized that there is much additional research being pursued in this area which would be potentially valuable to NASA and could, with some stimulation from, be made more applicable to NASA's needs. It is hoped, therefore, that the proceedings of this conference will be used as the basis for developing research strategies to be used as a road map to point the way in which NASA's own sponsored program should proceed over the course of the next three years. Additionally, it is hoped that the conference will highlight additional areas in which NASA should be involved either in-house or through the sponsorship of non-NASA scientists. NASA would also like to get an idea of which areas should be emphasized or perhaps de-emphasized among those that it is currently pursuing. In considering these questions, the discussion should concern itself not so much with whether a particular procedure or piece of equipment would work in a spacecraft, but rather, with whether the procedures that are advocated are at the state-of-the-art or beyond the state-of-the-art and whether they hold promise of giving additional insight into the problems to be confronted as humans venture into space for longer and longer periods of time.

Source record↗

NASA NTRS1977

Conceptual design of single turbofan engine powered light aircraft

The conceptual design of a four place single turbofan engine powered light aircraft was accomplished utilizing contemporary light aircraft conventional design techniques as a means of evaluating the NASA-Ames General Aviation Synthesis Program (GASP) as a preliminary design tool. In certain areas, disagreement or exclusion were found to exist between the results of the conventional design and GASP processes. Detail discussion of these points along with the associated contemporary design methodology are presented.

Snyder, F. S.↗

NASA NTRS1987

Research and Technology

Selected achievements at the Ames-Moffett and Ames-Dryden sites of the Ames Research Center are illustrated. The challenging work that was accomplished in the past year is presented for the following areas: engineering and technical services, aerospace systems, flight operations and research, aerophysics, and space research.

Source record↗

NASA NTRS2002

Mars-Gram Validation with Mars Global Surveyor Data

Mars Global Reference Atmospheric Model (Mars-GRAM 2001) is an engineering-level Mars atmosphere model widely used for many b4ars mission applications. From 0-80 km, it is based on NASA Ames Mars General Circulation Model (MGCM), while above 80 km it is based on University of Arizona Mars Thermospheric General Circulation Model. Mars-GRAM 2001 and MGCM use surface topography from Mars Global Surveyor Mars Orbiting Laser Altimeter (MOLA). Validation studies are described comparing Mars-GRAM with Mars Global Surveyor Radio Science (RS) and Thermal Emission Spectrometer (TES) data. RS data from 2480 profiles were used, covering latitudes 75deg S to 72deg N, surface to approx. 40 km, for seasons ranging from areocentric longitude of Sun (Ls) = 70-160deg and 265-310deg. RS data spanned a range of local times, mostly 0-9 hours and 18-24 hours. For interests in aerocapture and precision landing, comparisons concentrated on atmospheric density. At a fixed height of 20 km, measured RS density varied by about a factor of 2.5 over the range of latitudes and Ls values observed. Evaluated at matching positions and times, average RS/Mars-GRAM density ratios were generally lf0.05, except at heights above approx. 25 km and latitudes above approx.50deg N. Average standard deviation of RS/Mars-GRAM density ratio was 6%. TES data were used covering surface to approx. 40 km, over more than a full Mars year (February, 1999 - June, 2001, just before start of Mars global dust storm). Depending on season, TES data covered latitudes 85deg S to 85deg N. Most TES data were concentrated near local times 2 hours and 14 hours. Observed average TES/Mars-GRAM density ratios were generally 1+/-0.05, except at high altitudes (15-30 km, depending on season) and high latitudes (> 45deg N), or at most altitudes in the southern hemisphere at Ls approx. 90 and 180deg). Compared to TES averages for a given latitude and season, TES data had average density standard deviation about the mean of approx. 6.5-10.5% (varying with height) for all data, or approx. 5- 12%, depending on time of day and dust optical depth. Average standard deviation of TES/Mars-GRAM density ratio was 8.9% for local time 2 hours and 7.1% for 1o:al time 14 hours. Thus standard deviation of observed TES/Mars-GRAM density ratio, evaluated at matching positions and times, is about the same as the standard deviation of TES data about the TES mean value at a given position and season.

Justus, C. G.↗

NASA NTRS2002

Global Summary MGS TES Data and Mars-Gram Validation

Mars Global Reference Atmospheric Model (Mars-GRAM 2001) is an engineering-level Mars atmosphere model widely used for many Mars mission applications. From 0-80 km, it is based on NASA Ames Mars General Circulation Model (MGCM), while above 80 km it is based on University of Arizona Mars Thermospheric General Circulation Model. Mars-GRAM 2001 and MGCM use surface topograph$ from Mars Global Surveyor Mars Orbiting Laser Altimeter (MOLA). Validation studies are described comparing Mars-GRAM with a global summary data set of Mars Global Surveyor Thermal Emission Spectrometer (TES) data. TES averages and standard deviations were assembled from binned TES data which covered surface to approx. 40 km, over more than a full Mars year (February, 1999 - June, 2001, just before start of a Mars global dust storm). TES data were binned in 10-by-10 degree latitude-longitude bins (i.e. 36 longitude bins by 19 latitude bins), 12 seasonal bins (based on 30 degree increments of Ls angle). Bin averages and standard deviations were assembled at 23 data levels (temperature at 21 pressure levels, plus surface temperature and surface pressure). Two time-of day bins were used: local time near 2 or 14 hours local time). Two dust optical depth bins wereused: infrared optical depth either less than or greater than 0.25 (which corresponds to visible optical depth either less than or greater than about 0.5). For interests in aerocapture and precision entry and landing, comparisons focused on atmospheric density. TES densities versus height were computed from TES temperature versus pressure, using assumptions of perfect gas law and hydrostatics. Mars-GRAM validation studies used density ratio (TES/Mars-GRAM) evaluated at data bin center points in space and time. Observed average TES/Mars-GRAM density ratios were generally 1+/-0.05, except at high altitudes (15-30 km, depending on season) and high latitudes (> 45 deg N), or at most altitudes in the southern hemisphere at Ls approx. 90 and 180deg). Compared to TES averages for a given latitude and season, TES data had average density standard deviation about the mean of approx. 65-10.5% (varying with height) for all data, or approx. 5-12%, depending on time of day and dust optical depth. Average standard deviation of TES/Mars-GRAM density ratio was 8.9% for local time 2 hours and 7.1% for local time 14 hours. Thus standard deviation of observed TES/Mars-GRAM density ratio, evaluated at matching positions and times, is about the same as the standard deviation of TES data about the TES mean value at a given position and season.

Justus, C.↗

NASA NTRS2003

Mars Global Reference Atmospheric Model (Mars-GRAM) and Database for Mission Design

Mars Global Reference Atmospheric Model (Mars-GRAM 2001) is an engineering-level Mars atmosphere model widely used for many Mars mission applications. From 0-80 km, it is based on NASA Ames Mars General Circulation Model, while above 80 km it is based on Mars Thermospheric General Circulation Model. Mars-GRAM 2001 and MGCM use surface topography from Mars Global Surveyor Mars Orbiting Laser Altimeter. Validation studies are described comparing Mars-GRAM with Mars Global Surveyor Radio Science and Thermal Emission Spectrometer data. RS data from 2480 profiles were used, covering latitudes 75 deg S to 72 deg N, surface to approximately 40 km, for seasons ranging from areocentric longitude of Sun (Ls) = 70-160 deg and 265-310 deg. RS data spanned a range of local times, mostly 0-9 hours and 18-24 hours. For interests in aerocapture and precision landing, comparisons concentrated on atmospheric density. At a fixed height of 20 km, RS density varied by about a factor of 2.5 over ranges of latitudes and Ls values observed. Evaluated at matching positions and times, these figures show average RSMars-GRAM density ratios were generally 1+/-)0.05, except at heights above approximately 25 km and latitudes above approximately 50 deg N. Average standard deviation of RSMars-GRAM density ratio was 6%. TES data were used covering surface to approximately 40 km, over more than a full Mars year (February, 1999 - June, 2001, just before start of a Mars global dust storm). Depending on season, TES data covered latitudes 85 deg S to 85 deg N. Most TES data were concentrated near local times 2 hours and 14 hours. Observed average TES/Mars-GRAM density ratios were generally 1+/-0.05, except at high altitudes (15-30 km, depending on season) and high latitudes (greater than 45 deg N), or at most altitudes in the southern hemisphere at Ls approximately 90 and 180 deg. Compared to TES averages for a given latitude and season, TES data had average density standard deviation about the mean of approximately 2.5% for all data, or approximately 1-4%, depending on time of day and dust optical depth. Average standard deviation of TES/Mars-GRAM density ratio was 8.9% for local time 2 hours and 7.1% for local time 14 hours. Thus standard deviation of observed TES/Mars-GRAM density ratio, evaluated at matching positions and times, is about three times the standard deviation of TES data about the TES mean value at a given position and season.

Justus, C. G.↗

NASA NTRS2015

Planetary Protection Knowledge Gaps for Human Extraterrestrial Missions: Workshop Report

This report on Planetary Protection Knowledge Gaps for Human Extraterrestrial Missions summarizes the presentations, deliberations and findings of a workshop at NASA Ames Research Center, March 24-26, 2015, which was attended by more than 100 participants representing a diverse mix of science, engineering, technology, and policy areas. The main objective of the three-day workshop was to identify specific knowledge gaps that need to be addressed to make incremental progress towards the development of NASA Procedural Requirements (NPRs) for Planetary Protection during human missions to Mars.

Race, Margaret S.↗

NASA NTRSDate not supplied

PowerCell aboard the EuCROPIS satellite - Results from the first synthetic biology experiment in space

Synthetic biology is the design and construction of new biological parts and systems not found in nature, a technology that we believe will be a game-changing technology for space exploration. The PowerCell concept is an ecology based on photosynthetic microbes taking advantage of in situ materials and energy to generate, on-demand, useful products (food, fuel, cloths, drugs, etc.) that satisfy specific needs of long-term human presence away from Earth. This first PowerCell experiment is testing this concept as well as several key mechanisms of engineering biology in a 48-well plate microfluidics system. NASA's PowerCell experiment was loaded in the fluidics system at NASA Ames in May 2016, and subsequently integrated on the DLR's compact satellite Eu:CROPIS (Euglena Combined Regenerative Organic food Production In Space), as a secondary payload. Launched into Earth’s orbit from the Vandenberg Air Force Base, California, USA, in December 3, 2019, the Eu:CROPIS platform has provided an artificial gravity through rotational acceleration, simulating gravity ranges compatible to those found on Mars and on the Moon, as well as microgravity in the absence of acceleration. Each set of biological experiments performed at Earth's orbit was compared to ground controls. Over 400 days' worth of mission data showed that all hardware and software worked as planned, and microbial growth was observed in all four gravity regimes, including growth on cyanobacterial cell extract in three out of four gravity regimes. The genetic transformation experiment was successful in microgravity and provided valuable long-term reagent stability data, including antibiotic efficacy. The demonstrated ability of hardy bacterial spores to recover from a long-term stasis period will be fundamental for deep human space missions. Lessons learned from hardware design to experimental operations are leading to improved designs and capabilities for future missions.

Ivan Glaucio Paulino Lima↗

DOE OSTI2025

You Only Look Once v5 and Multi-Template Matching for Small-Crack Defect Detection on Metal Surfaces

This paper compares the performance of Deep Learning (DL) and multi-template matching (MTM) models for detecting small defects. DL models extract distinguishing features of objects but require a large dataset of images. In contrast, alternative computer vision techniques like MTM need a relatively small dataset. The lack of large datasets for small metal-surface defects has inhibited the adoption of automation in small-defect detection in remanufacturing settings. This motivated this preliminary study to compare template-based approaches, like MTM, with feature-based approaches, such as DL models, for small-defect detection on an initial laboratory and remanufacturing industry dataset. This study used You Only Look Once v5 (YOLOv5) as the DL model and compared its performance against the MTM model for small-crack detection. The findings of our preliminary investigation are as follows: (i) YOLOv5 demonstrated higher performance than MTM in detecting small cracks; (ii) an extra-large variant of YOLOv5 outperformed a small-size variant; (iii) the size and object variety of the data are crucial in achieving robust pre-trained weights for use in transfer learning; and (iv) enhanced image resolution contributes to precise object detection.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1991

Representing cockpit crew decision making

A theoretical framework has been synthesized for the use of cognitive processes to understand team functions. Three different pilot-copilot-flight engineer cockpit crews were observed over the course of a set of mission conducted in a B 727 simulator at NASA-Ames. Only experienced commercial aviators were used in positions for which they were officially qualified; one of the flights involved a generator malfunction, and another was marked by a serious fuel leak. All flights were videotaped and shown to the crews immediately after each session. Transcripts prepared from these videotapes logged the person uttering each comment and the exact time of the comment.

Klein, Gary A.↗