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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 OSTI2026

Influence of Surface Treatment on the Interfacial and Mechanical Performance of Metal-Insert Overmolded Composites

Structural composites with metal inserts are gaining increasing interest enabling light weight design for energy efficiency, provide insulation, corrosion protection without compromising mechanical integrity. Such over molded metal-polymer composites show strong potential in many automotive and aerospace component parts, e.g. car bumper, chassis, door, brackets, fasteners, etc. Despite several advantages, metal-polymer dissimilar interface remains a weak spot in structural design, requiring further investigation to improve interfacial interlocking. The current work focuses on enhancing the metal-polymer adhesion between stainless steel inserts and polymer matrices (e.g. acrylonitrile butadiene styrene resin (ABS), and polyamide 66 (PA66) through surface treatment via chemical etching and mechanical roughening. In the chemical etching process, metal substrates were treated with aqua regia solution for different time intervals to evaluate surface roughness measured by water contact angle and morphology analysis. For mechanical roughening approach, metal inserts were subjected to blasting for surface abrasion. Treated samples were also functionalized with aminosilane coupling agent which showed successful grafting on the surface measured by water contact angle. Metal inserts with micro level surface roughness through etching exhibited significant 21% improvement in adhesion strength compared to untreated inserts; however, the effect of silane treatment on the interfacial strength was found to be highly matrix dependent.

Saha, Subhabrata [ORNL] (ORCID:000000033966064X)↗
NASA NTRS1989

Turbomachinery shaft insert

An insert is presented for a hollow rotatable shaft on the end of which an impeller is mounted, the insert having a first cylindrical portion receivable within the end of the shaft. The insert includes a radially extending portion adjacent the end of the shaft having an annular wall including radially inner and outer surfaces for engaging tightly similar surfaces in a recess formed in the impeller to provide inner and outer pilot surfaces. The insert also includes a tubular extension which is received within a bore in the impeller, the tubular extension having spaced longitudinally extending slits for permitting the extension together with radially extending hook-like tongues thereon to be received within radial slots in the bore of the impeller to lock the impeller to the insert.

Vonpragenau, George L.↗
NASA NTRS1991

Tool Removes Coil-Spring Thread Inserts

Tool removes coil-spring thread inserts from threaded holes. Threads into hole, pries insert loose, grips insert, then pulls insert to thread it out of hole. Effects essentially reverse of insertion process to ease removal and avoid further damage to threaded inner surface of hole.

Collins, Gerald J., Jr.↗
NASA NTRS1992

Screw-Thread Inserts As Temporary Flow Restrictors

Coil-spring screw-thread inserts found useful as temporary flow restrictors. Inserts placed in holes through which flow restricted, effectively reducing cross sections available for flow. Friction alone holds inserts against moderate upstream pressures. Use of coil-spring thread inserts as flow restrictors conceived as inexpensive solution to problem of adjusting flow of oxygen through orifices in faceplate into hydrogen/oxygen combustion chamber. Installation and removal of threaded inserts gentle enough not to deform orifice tubes.

Trimarchi, Paul↗
NASA NTRS2000

Insert Concepts for the Material Science Research Rack (MSRR-1) of the Material Science Research Facility (MSRF) on the International Space Station (ISS)

The Material Science Research Rack I (MSRR-1) of the Material Science Research Facility (MSRF) contains an Experiment Module (EM) being developed collaboratively by NASA and the European Space Agency (ESA). This NASA/ESA EM will accommodate several different removable and replaceable Module Inserts (MIs) which are installed on orbit NASA's planned inserts include the Quench Module Insert (QMI) and the Diffusion Module Insert (DMI). The QMI is a high-gradient Bridgman-type vacuum furnace with quench capabilities used for experiments on directional solidification of metal alloys. The DMI is a vacuum Bridgman-Stockbarger-type furnace for experiments on Fickian and Soret diffusion in liquids. This paper discusses specific design features and performance capabilities of each insert. The paper also presents current prototype QMI hardware analysis and testing activities and selected results.

Crouch, Myscha↗
NASA NTRS2019

Systems and Methods for Structurally Interrelating Components Using Inserts Made from Metallic Glass-Based Materials

Systems and methods in accordance with embodiments of the invention operate to structurally interrelate two components using inserts made from metallic glass-based materials. In one embodiment, a method of structurally interrelating two components includes: forming an insert from a metallic glass-based composition; where the formed insert includes a metallic glass-based material; affixing the insert to a first component; and structurally interrelating the second component to the first component using the insert.

Hofmann, Douglas C.↗
DOE OSTI2025

Σ3(111) Grain Boundaries Accelerate Hydrogen Insertion into Palladium Nanostructures

Grain boundaries (GBs) are frequently implicated as key defect structures facilitating metal hydride formation, yet their specific role remains poorly understood due to their structural complexity. Here, we investigate hydrogen insertion in Pd nanostructures enriched with well-defined Σ3(111) GBs (Pd GB ) synthesized via electrolysis-driven nanoparticle assembly. In situ synchrotron X-ray diffraction reveals that Pd GB exhibits dramatically accelerated hydriding and dehydriding kinetics compared with ligand-free and ligand-capped Pd nanoparticles with similar crystallite sizes. Strain mapping using environmental transmission electron microscopy shows that strain is highly localized at GBs and intensifies upon hydrogen exposure, indicating preferential hydrogen insertion along GB sites. Density functional theory calculations provide mechanistic insight supporting these findings, showing that hydrogen insertion near Σ3(111) GBs is energetically more favorable and that tensile strain lowers insertion barriers. Furthermore, these results provide atomic-level insights into the role of GBs in hydride formation and suggest new design strategies for GB-engineered Pd-based functional materials.

Anions↗
DOE OSTI2025

CFD Simulations of Molten Salts Within Plasma-Facing Components with Twisted Tape Inserts Under One-Sided–Heated Conditions

For liquid immersion blankets (LIBs), the heat removal within different plasma-facing components (PFCs) requires substantial heat removal capabilities that could benefit from the usage of heat transfer enhancements. Of consideration are twisted tape insert heat transfer enhancements that are ribbon-like metal pieces inserted within cooling channels that increase fluid mixing, resulting in higher heat transfer and pressure drop. Unlike traditional applications, PFCs such as divertor coolant tubes experience a significantly higher heat flux on one side versus the other or entirely one-sided heating. These conditions are not well studied for molten salts where the higher Prandtl numbers characteristic of the fluids are significantly higher than water, gases, and liquid metals. As an effort to study this knowledge gap, large eddy simulations were done with Prandtl numbers representative of FLiBe at proposed operating conditions. In this study, the effects of applying a surface heat flux to one side of a tube versus the entire tube with a twisted tape insert were investigated for the heat transfer coefficient and effects on the temperature profile. The findings of the study suggest that for Prandtl number fluids above unity, the Nusselt number was largely unaffected by the change in boundary condition. Both boundary conditions showed good agreement with the Manglik and Bergles Nusselt number correlation for tight-fitting twisted tapes. Finally, the outcomes of this study will be useful for future design studies of LIBs to provide fundamental guidance implementing twisted tape inserts and their performance in one-sided–heated conditions.

molten salts↗
DOE OSTI2025

Improving Longitudinal Impedance of Inductive Inserts

In this article, we discuss methods for improving the longitudinal impedance of inductive inserts used for space charge compensation in the proton storage ring (PSR) at Los Alamos Neutron Science Center (LANSCE) Facility. The PSR relies on inductive inserts to counteract the capacitive impedance produced by the space charge of the proton beam, which can otherwise lead to beam debunching. Existing inductive inserts, which utilize Toshiba M4C21A ferrite, have been effective but require heating to reduce resistive components that can cause instabilities at higher frequencies. This article explores the potential of alternative ferrite materials, specifically National Magnetics C2050, to enhance the performance of these inserts by reducing the need for heating and minimizing resistive impedance. Through both analytical modeling and CST Particle Studio simulations, it is demonstrated that optimized ferrite materials and geometries can significantly improve space charge compensation while mitigating instability risks, ultimately enhancing the performance of the PSR.

43 PARTICLE ACCELERATORS↗
NASA NTRS2019

Departure Approval Request Compliance Effects on Overhead Stream Insertion

Integrated Arrival-Departure-Surface (IADS) air traffic management relies on information sharing and integration between automation systems for efficiency, predictability, and throughput improvements throughout the National Airspace System (NAS). The NASA Airspace Technology Demonstration 2 (ATD-2) project supports this effort by integrating SWIM (System Wide Information Management) information and evaluating and refining potential TFDM (Terminal Flight Data Manager) functionality in a surface traffic management system fielded at Charlotte-Douglas International Airport (CLT). Among the IADS areas under study during ATD-2 is the use of electronically negotiated departure times for efficiently inserting flights into overhead traffic streams. Stream-insertion accuracy is important for reducing excessive vectoring that negatively impacts the NAS by increasing controller workload along with aircraft fuel burn and emissions. Departure-time approval requests (APREQs) provide center-approved departure times to allow for smooth stream insertion. In this presentation, TBFM (Time-Based Flow Management) and ATD-2 flight summary data are used to empirically show that APREQ compliance leads to improved stream insertion.

Overhead-Stream Insertion↗
DOE OSTI2026

Construct design for precise DNA insertion in plants

Precise insertion of DNA sequences at targeted locations in plant genomes is pivotal for synthetic biology, genetics, and crop improvement. Construct design plays a critical role in achieving precise insertions, yet practical guidance remains limited. This review provides an in-depth overview of construct design principles and targeted DNA insertion (knock-in) strategies in plants. We assess the strengths, limitations, and construct requirements of current knock-in methods for specific applications, including short, large, and multifragment insertions. Additionally, we explore the potential of adopting advanced nonplant technologies to enhance knock-in efficiency and precision in plants. This review provides a valuable resource for facilitating the effective application of knock-in technologies to genetically improve crops with minimal off-target effects.

DNA construct↗
DOE OSTI2025

Simulations of Heat Transfer Using Tight-Fitting Twisted Tape Inserts for First Wall Cooling in Molten Salt Breeder Blankets

One of the major components in fusion energy systems is the fusion blanket, which has a vacuum vessel to contain the plasma. As part of the fusion blanket/vacuum vessel, the first wall and plasma-facing components require sufficient cooling to prevent material degradation during operation from the superheated plasma. Most fusion blanket concepts involve first wall and divertor coolant channels with heat transfer enhancements (HTEs) that are intended to withstand the incident high heat fluxes of 1 to 5 MW/m 2 . Twisted tape inserts are a proposed HTE that have been investigated previously for first wall cooling and monoblock divertor cooling channels and in other nonfusion heat transfer components. By inserting twisted tapes into straight pipes, the amount of turbulence in the system can be increased at lower Reynolds numbers by swirling the flow. This results in better heat transfer characteristics with marginal increases in frictional pressure losses. In particular, simulations of high-Prandtl-number fluids such as the proposed molten salt FLiBe in twisted tapes, which is prototypic to liquid immersion blankets, have not been previously explored. Here, in this study, we simulate various Prandtl numbers in pipes with twisted tape inserts using large eddy simulations to determine the effects of increasing Prandtl numbers on heat transfer performance. The quantities of particular interest are the Nusselt number and the friction factor, which were recovered using data reduction techniques to determine impacts on heat transfer and pressure losses. This work serves as a starting point for determining the feasibility of twisted tape inserts for liquid immersion blanket concepts.

LES↗
DOE OSTI2025

Suppressing Screening-Current-Induced Strain in a 72-mm-Bore REBCO Insert for a 20-T Magnet: A Numerical Study

Rare-earth barium copper oxide (REBCO) high-temperature superconducting (HTS) magnets are considered a game changer for the capability of generating magnetic fields exceeding 20 T at or above liquid helium temperature, combined with the potential for substantially reduced manufacturing and operational costs. Princeton Plasma Physics Laboratory is dedicated to developing large-bore high-field superconducting magnet systems to support forefront physics research. Here, our current project focuses on a φ72-mm cold-bore REBCO insert comprising 21 dry-wound double-pancake coils, designed to generate at least 8 T when nested within a 12-T outsert magnet. A significant challenge for high-field REBCO magnets is the time-varying-magnetic-field-induced screening currents (SC) in the REBCO conductors, which can cause localized strain and stress concentrations. This paper presents a numerical study of the SC-induced strain in the REBCO insert magnet, confirming that the SC-induced strain can be substantially suppressed by energizing the REBCO insert before the outsert magnets. We discuss and reveal the mechanism behind this reduction. By applying this strategy, we expect to unleash the potential of the REBCO insert magnet to generate up to 12 T in a 12-T background field.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1975

Interfacial insert for electrical connectors

The development of interfacial inserts for improved electric connectors is discussed. The inserts were manufactured from epoxy resins. The design features of the inserts and the manufacturing equipment are described. The reliability test program is reported. Drawings of the interfacial inserts are provided.

Macavay, D.↗
NASA NTRS1981

Wind tunnel supplementary Mach number minimum section insert

A device is described which changes the Mach number capability of a wind tunnel without permanently altering the existing nozzle of the tunnel. An insert is removably attached to the wall of the existing nozzle expansion area thereby creating a second minimum section upstream of the model test section. The added insert may be removed without complicated and expensive changes to the basic wind tunnel. In one embodiment, a removable insert is disposed within wind tunnel nozzle walls with a portion of the flow boundary layer being bled off from the tunnel via passageway and tunnel exit to reduce the extent of separated flow normally occuring upstream of the insert contraction section.

Couch, L. M.↗
NASA NTRS1984

Laboratory tests on an aircraft fuselage to determine the insertion loss of various acoustic add-on treatments

This paper describes a laboratory study of add-on acoustic treatments for a propeller-driven light aircraft fuselage. The treatments included: no treatment (i.e., baseline fuselage); a production-type double-wall interior; and various amounts of high density fiberglass added to the baseline fuselage. The sound source was a pneumatic-driver with attached exponential horn, supplied with a broadband signal. Data were acquired at the approximate head positions of the six passenger seats. The results were analyzed on space-averaged narrowband, one-third octave band and overall insertion loss basis. In addition, insertion loss results for the different configurations at specific frequencies representing propeller tone spectra are presented. The propeller tone data includes not only the space-averaged insertion loss, but also the variation of insertion loss at these particular frequencies across the six microphone positions.

Heitman, K. E.↗
NASA NTRS1986

Thrust improvement with ablative insert nozzle extension

Aspects are examined of an investigation by the Marshall Space Flight Center into the conceptual feasibility of increasing the thrust performance of the Space Shuttle Main Engine (SSME) by using a conical nozzle extension fitted with an ablative insert in order to achieve a low-cost, near-term gain in payload. The ablating insert would provide a controlled increase in nozzle expansion ratio during launch and early climbout (first 30-60 seconds) so as to reduce thrust loss from nozzle over-expansion in the lower atmosphere. Summaries are given of JPL studies in the area of: defining the near-wall flow environment in the extended nozzle insert region; selecting potential insert materials; conceptualizing an extension/insert geometrical configuration; and identifying future experimental efforts necessary to verify the feasibility of the concepts.

Clayton, R. M.↗
NASA NTRS1989

Predeployment validation of fault-tolerant systems through software-implemented fault insertion

Fault injection-based automated testing (FIAT) environment, which can be used to experimentally characterize and evaluate distributed realtime systems under fault-free and faulted conditions is described. A survey is presented of validation methodologies. The need for fault insertion based on validation methodologies is demonstrated. The origins and models of faults, and motivation for the FIAT concept are reviewed. FIAT employs a validation methodology which builds confidence in the system through first providing a baseline of fault-free performance data and then characterizing the behavior of the system with faults present. Fault insertion is accomplished through software and allows faults or the manifestation of faults to be inserted by either seeding faults into memory or triggering error detection mechanisms. FIAT is capable of emulating a variety of fault-tolerant strategies and architectures, can monitor system activity, and can automatically orchestrate experiments involving insertion of faults. There is a common system interface which allows ease of use to decrease experiment development and run time. Fault models chosen for experiments on FIAT have generated system responses which parallel those observed in real systems under faulty conditions. These capabilities are shown by two example experiments each using a different fault-tolerance strategy.

Czeck, Edward W.↗