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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Colorado Alternatively Powered Aircraft Airport Infrastructure Study

Advanced Air Mobility encompasses emerging technologies in propulsion of general aviation and commuter aircraft for the purpose of moving passengers and goods. The State of Colorado has a strong aerospace and aviation legacy, and this research explores the potential energy implications of a transition from traditional aircraft propulsion systems to more-electric, full electric and hydrogen powered aircraft in flight schools, and small community air service utilizing NASA's Regional Air Mobility Model. Effort includes identifying potential energy needs and cost-effective solutions to support those emerging needs analyzing potential benefits on on-site generation and storage to optimize energy systems.Advanced Air Mobility encompasses emerging technologies in propulsion of general aviation and commuter aircraft for the purpose of moving passengers and goods. The State of Colorado has a strong aerospace and aviation legacy, and this research explores the potential energy implications of a transition from traditional aircraft propulsion systems to more-electric, full electric and hydrogen powered aircraft in flight schools, and small community air service utilizing NASA's Regional Air Mobility Model. Effort includes identifying potential energy needs and cost-effective solutions to support those emerging needs analyzing potential benefits on on-site generation and storage to optimize energy systems.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Nuclear Materials Packaging, Transportation, and Systems Analysis Group Software Quality Assurance Plan: ANSYS Mechanical Finite Element Analysis Software Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic, and electromagnetic simulation capabilities. ANSYS has two main programs, which use the same solvers: (1) Mechanical APDL (ANSYS Design Parametric Language), a Fortran-based coding platform, and (2) ANSYS Workbench, which uses a graphical user interface to aid in finite element analysis implementation. This plan covers both APDL and Workbench. The ANSYS computer program is a large-scale, multipurpose finite element program that can be used to solve several classes of engineering analyses. The analysis capabilities of ANSYS include the ability to solve static and dynamic structural analyses, steady-state and transient heat transfer problems, mode-frequency and buckling eigenvalue problems, static or time-varying magnetic analyses, and various types of field and coupled-field applications. The program contains many special features that allow nonlinearities or secondary effects such as plasticity, large strain, hyperelasticity, creep, swelling, large deflections, contact, stress stiffening, temperature dependency, material anisotropy, and radiation to be included in the solution. As ANSYS has been developed, other special capabilities such as substructuring, submodeling, random vibration, kinetostatics, kinetodynamics, free convection fluid analysis, acoustics, magnetics, piezoelectrics, coupled-field analysis, and design optimization have been added to the program. These capabilities contribute further to making ANSYS a multipurpose analysis tool for varied engineering disciplines. The ANSYS program has been in commercial use for over 50 years and has been used extensively in the aerospace, automotive, construction, electronic, energy services, manufacturing, nuclear, plastics, oil, and steel industries. Additionally, many consulting firms and hundreds of universities have used ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. Ansys design analysis software is the first created within a quality system with ISO 9001 certification, the internationally accepted quality standard. Product development, testing, maintenance and support processes also meet the United States Nuclear Regulatory Commission's quality requirements, as they have for nearly four decades. The Quality Assurance Service Agreement is suitable for the customers working in the nuclear industry who need to meet specific federal regulations including 10CRF50 Appendix B and provisions of 10CFR21. ANSYS has retained its original International Organization for Standardization (ISO) 9001 accreditation certificate since1995-05-04, It’s current certificate is valid until 2027-05-29.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Full-Strength Additive Manufacturing of Pure Aluminum Alloy 7075 Using Liquid Metal Jet Printing

Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Scalable foundation models for numerical simulations on HPC platforms

In recent years, foundation models (FMs) have begun to reshape numerical simulations on high-performance computing (HPC) platforms. These large, pre-trained AI models enable rapid predictions across a broad range of physical domains, including Earth system modeling, fluid dynamics, materials science, as well as complex multi-modal simulations in aerospace engineering and fusion research. By training on diverse datasets, FMs learn intricate relationships and underlying physical behavior while also enabling the quantification of uncertainty in their predictions. This capability allows simulations that once required days of numerical calculation to be completed in minutes (FM inference), supporting real-time design optimization, uncertainty-aware decision making, and more comprehensive exploration of complex scenarios.

AI↗
DOE OSTI2025

The Global Spectra-Trait Initiative: A database of paired leaf spectroscopy and functional traits associated with leaf photosynthetic capacity (v1.0.0)

The Global Spectra-Trait Initiative (GSTI) aims to generate generalizable spectra trait models using reflectance data to predict leaf traits associated with the photosynthesis capacity of leaves. It comprises a synthesized dataset of leaf trait data, input datasets and code. Leaf traits include the maximum carboxylation rate of rubisco (Vcmax), the maximum electron transport rate (Jmax), the dark respiration, as well as the prediction of leaf nitrogen, leaf mass per area (LMA), and leaf water content (LWC). The dataset comprises >7500 paired observations from around 400 species from a broad range of biomes. This dataset comprises a zip file of the GSTI GitHub repository (https://github.com/plantphys/gsti), the synthesized database (.csv) and database metadata files. This dataset was updated on 2025-12-12 with minor edits to mirror the accepted manuscript version and GitHub release (Version 1.0.0 (ESSD accepted version)). Edits included minor changes to the project documentation on GitHub and removal of 12 duplicate entries from the database.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Operation at Reduced Atmospheric Pressure and Concept of Reliability Redundancy for Optimized Design of Insulation Systems

Electrified transportation is calling for insulation design criteria that is adequate to provide elevated levels of power density, power dynamics and reliability. Increasing voltage levels are expected to cause accelerated intrinsic and extrinsic aging effects which will not be easily predictable at the design stage due to a lack of suitable modeling. Designing reliable insulation systems would require finding solutions able to control accelerated aging due to an unpredictable increase of intrinsic stresses and the onset of extrinsic stresses as partial discharges. This paper proposes the concept of reliability redundancy for the insulation design of aerospace electrical asset components, which is also validated at lower-than-standard atmospheric pressure. The principle is that extrinsic-aging-free design might be achieved upon determining the aging stress or abnormal service stresses distribution and being sure that aging will not generate conditions that can incept extrinsic aging (partial discharges) during operation life. However, such information is never, in practice, fully available to insulation system designers. Hence, especially in critical applications such as electrified aircraft, aerospace, and combat ships a further level of reliability should be added to a partial-discharge-free design, which can consist of the use of corona-resistant materials and/or of life models able to consider the accelerated aging effect of partial discharges (or any other type of extrinsic-accelerated aging factor). Innovative life modeling considering both extrinsic and intrinsic aging stresses, insulating material testing to estimate model parameters, and a metric for quantifying the extent of corona (or partial discharge) resistance can lead to establishing feasibility and limit conditions for optimized or fully reliability-redundant design. It is shown in the paper that if an extrinsic-aging-free design is not feasible, and it is therefore replaced by a redundant design, a further level of reliability redundancy can be provided by effective condition monitoring plans.

Montanari, Gian Carlo↗
DOE OSTI2025

Densification, microstructure, and mechanical properties of Mo–30W alloys fabricated from conditioned powders

Refractory alloys, such as molybdenum-based systems, are attracting growing interest for applications in extreme environments, such as in the nuclear and aerospace industries. Recent advances in sintering technologies, coupled with mechanical alloying, have enabled the tailored design of these alloys by leveraging powder characteristics to control final microstructures and mechanical properties. In this study, Mo-30W alloys were fabricated using electric field-assisted sintering (EFAS) from ball-milled powders with and without hydrogen treatment to investigate the influence of surface oxides on material properties and sintering behavior. The results revealed that samples processed from as-ball-milled powder contained a high density of oxides within the microstructure, whereas oxide presence was significantly reduced in samples fabricated from hydrogen-treated powders. Interestingly, the two powder types led to opposite trends in grain size distribution: samples from untreated powders exhibited grain refinement from sample periphery to the center, while samples from hydrogen-treated powders showed grain coarsening toward the center. This behavior is attributed to temperature gradients present during sintering due to electrical percolation pathway differences during Joule heating. The powder surface oxides may have influenced the temperature distribution and grain evolution. Microhardness profiles measured along both axial and thickness directions were consistent with the grain size distribution. Furthermore, oxide films on powder surfaces have delayed densification by hindering particle necking and atomic diffusion during sintering.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗
DOE OSTI2026

Development and Full Load Demonstration of a 900°C Solid Particle Receiver for Concentrating Solar Power Applications - noLimits

Sandia National Laboratories (SNL) and the German Aerospace Centre (DLR) are world leaders in the joint and separate development of very high temperature next generation solar concentrator systems using solid particles. This project “noLimits” is meant to provide the critical performance information needed to commercialize DLR’s CentRec® solar receiver and ancillary particle systems (conveying systems, storage vessels, flow control equipment etc.) developed at Sandia National Laboratories (SNL). Performance information (at power levels closer to a small scale Concentrating Solar Power (CSP) plant) will be obtained at full load conditions (2.5 MWt ) and at 900 °C-1000 °C particle outlet temperatures at the National Solar Thermal Test Facility (NSTTF) located at SNL. Heliogen was proposed to be joining the project as a commercial partner to provide the commercialization route for this receiver design, if successful, as Heliogen acquired the intellectual property (IP) from DLR.

14 SOLAR ENERGY↗
DOE OSTI2026

MoNbTi-based Refractory Multi-principal Element Alloy System: A Review of the Thermodynamic Phase Predictions, Formed Microstructures, and Mechanical Properties as a Function of the Fabrication Methods (AM versus SPS versus VAM)

Abstract Multi-principal element alloys, particularly of refractory compositions, are an increasingly popular candidate for extreme-environment applications, including for next-generation nuclear reactors and in other industries, such as biomedical and aerospace, due to their high strength. The ability to achieve solid-solution microstructures provides these alloys with improved mechanical properties; however, these microstructures are heavily composition- and processing-dependent. In this review, the multi-principal element alloy MoNbTi-based system (with Zr, V, and Cr additions) was selected to compare the effects of elemental composition and processing route on the resulting microstructures and mechanical properties. The review provides insight into identifying the optimal alloy composition and processing route for a balance of desired microstructure and mechanical properties.

Krogh, Kara↗
DOE OSTI2026

3D Cloud Aerosol Precipitation Experiment at kennaook Cape Grim (3D-CAPE-k) Field Campaign Report

The objective of this campaign was to complement the U.S. Department of Energy Atmospheric Radiation Measurement (ARM) User Facility’s Cloud And Precipitation Experiment at kennaook (CAPE-k) in northwest Tasmania by deploying scanning, fixed pointing angle, and in situ aerosol, cloud, and precipitation remote-sensing instruments during the last six months of the experiment. These instruments provided a three-dimensional (3D) context to the second ARM Mobile Facility (AMF2) vertically pointing observations collected at the kennaook Cape Grim (KCG) site and captured a portion of the life cycle of the clouds before and after the passage over the AMF2 vertical column. These 3D cloud measurements will be used in the near future to 1) investigate how the vertical profiles of aerosol and cloud properties are representative of the broader area and how these properties evolve during the portion of the cloud life cycle captured by the scanning instruments, 2) quantify how accurate the cloud fraction derived with assumptions from vertically pointing observations are compared with direct 3D cloud fraction measurements, 3) evaluate cloud fraction and liquid water path in the Australian Community Climate and Earth-System Simulator–Convective-scale (ACCESS-C) forecast model, and 4) evaluate aerosol and cloud products from the European Space Agency/Japanese Aerospace Exploration Agency (ESA/JAXA) Earth Cloud Aerosol Radiation Explorer (EarthCARE) mission using the scanning measurements, offering more chances of exact collocation, thereby complementing the statistical approach we are planning to employ with AMF2 observations for that same purpose.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗
DOE OSTI2025

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗
DOE OSTI2025

XRISM spectroscopy on orbital modulation of Fe Ly α lines in Cygnus X-3

To understand physical processes such as mass transfer and binary evolution in X-ray binaries, the orbital parameters of the system are fundamental and crucial information. Cygnus X-3 is a high-mass X-ray binary composed of a compact object of unknown nature and a Wolf–Rayet star, which is of great interest in the context of wind-fed mass accretion and binary evolution. Here we present XRISM/Resolve high-resolution spectroscopy, focusing on the Fe Ly$\alpha$ lines when the source was in its hypersoft state. We perform an orbital phase-resolved spectral analysis of the lines to study the orbital modulation of the emission and absorption lines. It is found that the emission lines reflect the orbital motion of the compact object whose estimated velocity amplitude is $430^{+150}_{-140}$ km s$^{-1}$, while the absorption lines show a variation that can be interpreted as originating from the stellar wind. We discuss possible mass ranges for the binary components using the mass function with the estimated value of the velocity amplitude in this work, combined with the relation between the mass-loss rate and the orbital period derivative and the empirical mass and mass-loss rate relation for Galactic Wolf–Rayet stars. They are constrained to be (1.3–5.1) and (9.3–12) M$_\odot$, respectively, for the assumed inclination angle of $i =25^\circ$, and become more relaxed, (1.3–24) and (9.3–16) M$_\odot$, for $i = 35^\circ$. Thus, it remains unclear whether the system harbors a black hole or a neutron star.

X-rays: binaries↗