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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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NASA NTRSDate not supplied

TPSAS-NF1676L-32708-DND

Proposed Effort under Advanced Air Transport Technology (AATT): - Select advanced Al alloy with formability and additive manufacturability, high combined strength and toughness - Fabricate single-piece Integrally Stiffened Cylinders (~10 ft. dia. x 10 ft. long) with longitudinal stiffeners - Demonstrate joining technology for assembly of two cylinders into 20-ft. long fuselage structure - Optimize structural design incorporating tailored, selective reinforcement for durability and damage tolerance - Build-up window, door and circumferential ring frames with large-scale additive manufacturing - Structural test to validate manufacturing demonstration, structural models and analysis

Taminger, Karen M↗

DOE OSTI2025

Fused Deposition Modeling Additive Manufacturing of Carbonized Structures via Waste-Enhanced Filaments

This report details the development, characterization, and use of coal-enhanced composite materials in additive manufacturing applications. High coal loading formulations—containing up to 70 wt.% coal—were successfully extruded and processed using commercially available 3D printers. Extensive experimental testing was conducted to assess the mechanical, thermal, and microstructural properties of the composites. In parallel, multi-scale computational modeling was employed to elucidate atomistic interactions and evaluate the effects of printing-induced defects on structural performance. Large-scale printability trials demonstrated the feasibility of fabricating complex components for tooling and construction applications, including wind turbine blade molds and modular wall sections. Techno-economic analyses demonstrated the cost-effectiveness and scalability of coal-enhanced composites for large-scale additive manufacturing applications such as wind turbine blade tooling.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Epoxy Coating of Biofiber: An Effective Modifier of Biofiber Physical and Flow Properties for Improved Tensile Behavior of Biofiber-Reinforced Biocomposite

Biocomposites combine renewable, plant-based fibers with degradable polymers and are an attractive option for sustainable, lightweight, and cost-effective materials with a low carbon footprint, especially for large-scale additive manufacturing. One of the major challenges in the widespread adoption of biocomposites is that their mechanical performance is significantly inferior to that of synthetic composites. Surface treatment is a common and effective technique to improve the mechanical properties of the biofibers used in biocomposites. This study aims to investigate the physical and flow properties of surface-treated biofibers, as well as the tensile properties of their PLA-based biocomposite, to gain insights into how surface treatment changes the fiber‘s characteristics and biocomposite‘s mechanical properties. Surface treatment was created using a two-component epoxy system by reacting poly(bisphenol A-co-epichlorohydrin) glycidyl end-capped (PBG) and dicyandiamide (DICY). The treatment was tested on two different biofibers (loblolly pine and corn stover fibers) with three different PBG/DICY molar ratios (0.25, 0.5, and 2). Results showed that surface-treated fibers improved the tensile strength and Young‘s modulus of the biocomposites. Loblolly pine biocomposites from fibers treated with a PBG/DICY ratio of 0.25 exhibited the best tensile properties. The surface treatment resulted in a more loosely dispersed fiber bulk structure, as evidenced by less fiber agglomeration into smaller particle sizes, higher fiber sphericity, and lower loose bulk density. This can enhance stress distribution and the overall mechanical performance of the biocomposites. Additionally, surface-treated fibers exhibited better dynamic flow properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Propylamine Functionalized Porous Fiber Sorbents with High Oxidation Stability for Direct Air Capture

Amine-based sorbents are highly effective for direct air capture (DAC) due to their excellent CO2 capture efficiency under ultra-dilute conditions. However, these sorbents can suffer degradation when exposed to combinations of heat, oxygen, and other atmospheric components, indicating a need for improved sorbent stability. In this study, we developed amidoxime functionalized polymer of intrinsic microporosity (PIM-1-AO) fibers with tethered amines, specifically tris(2-aminoethyl)amine (TAEA) and tris(3-aminopropyl)amine (TAPA), denoted as PIM-1-AO-TAEA and PIM-1-AO-TAPA, respectively. In addition, large scale sorbent fiber spinning has been successfully performed by producing meters of fibers in the lab. We demonstrated that substituting TAEA with TAPA, which has propyl chains instead of ethyl chains, reduces oxidative degradation under regeneration conditions. The findings revealed that PIM-1-AO-TAPA not only significantly outperforms PIM-1-AO-TAEA after accelerated aging process, but also outperforms any other sorbent used in DAC aged under similar conditions. Moreover, PIM-1-AO-TAPA sorbent fibers showed one of the highest amine efficiencies (0.25) considering the low amine loading (21%) coupled with robust CO2 uptake performance (1.12 mmol/g) under DAC conditions.

amine-based sorbent↗

NASA NTRS1976

Preliminary feasibility study of pallet-only mode for magnetospheric and plasmas in space payloads, volume 4

Results of studies performed on the magnetospheric and plasma portion of the AMPS are presented. Magnetospheric and plasma in space experiments and instruments are described along with packaging (palletization) concepts. The described magnetospheric and plasma experiments were considered as separate entities. Instrumentation ospheric and plasma experiments were considered as separate entities. Instrumentation requirements and operations were formulated to provide sufficient data for unambiguous interpretation of results without relying upon other experiments of the series. Where ground observations are specified, an assumption was made that large-scale additions or modifications to existing facilities were not required.

Source record↗

NASA NTRS1982

Simulation of the fluctuating field of a forced jet

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected and the effect of nonlinearity is studied. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗

NASA NTRS1982

Simulation of the fluctuating field of a forced jet

Bayliss, A.↗

NASA NTRS1985

On the interaction of a sound pulse with the shear layer of an axisymmetric jet. Part 3: Nonlinear effects

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected, and the effect of nonlinearity was studied. A high order numerical method is used to compute the solution. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗

NASA NTRS1986

On the interaction of a sound pulse with the shear layer on an axisymmetric jet. III - Non-linear effects

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected, and the effect of nonlinearity is studied. A high order numerical method is used to compute the solution. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗

NASA NTRS2016

Rapid Fabrication Techniques for Liquid Rocket Channel Wall Nozzles

The functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.

Gradl, Paul R.↗

NASA NTRS2018

NASA's Centennial Challenge for 3D-Printed Habitat: Phase II Outcomes and Phase III Competition Overview

The 3D-Printed Habitat Challenge is part of NASA's Centennial Challenges Program. NASA's Centennial Challenges seek to accelerate innovation in aerospace technology development through public competitions. The 3D-Printed Habitat Challenge, launched in 2015, is part of the Centennial Challenges portfolio and focuses on habitat design and development of large-scale additive construction systems capable of fabricating structures from in situ materials and/or mission recyclables. The challenge is a partnership between NASA, Caterpillar (primary sponsor), Bechtel, Brick and Mortar Ventures, and Bradley University. Phase I of the challenge was an architectural concept competition in which participants generated conceptual renderings of habitats on Mars which could be constructed using locally available resources. Phase II asked teams to develop the printing systems and material formulations needed to translate these designs into reality. Work under the phase II competition, which concluded in August 2017 with a head to head competition at Caterpillar's Edward Demonstration Facility in Peoria, Illinois, is discussed, including the key technology development outcomes resulting from this portion of the competition. The phase III competition consists of both virtual and construction subcompetitions. Virtual construction asks teams to render high fidelity architectural models of a habitat and all the accompanying information required for construction of the pressure retaining and load bearing portions of the structure. In construction phase III, teams are asked to scale up their printing systems to produce a 1/3 scale habitat on-site at Caterpillar. The levels of the phase III construction competition (which include printing of a foundation and printing and hydrostatic testing of a habitat element) are discussed. Phase III construction also has an increased focus on autonomy, as these systems are envisioned for robotic precursor missions which would buildup infrastructure prior to the arrival of crew. Results of the phase III competition through July 2017 (which includes virtual construction level 1) are discussed. This Centennial Challenge enables an assessment of the scaleability and efficacy of various processes, material systems, and designs for planetary construction. There are also near-term terrestrial applications, from disaster response to affordable housing and infrastructure refurbishment, for these technologies.

Prater, T. J.↗

DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗

NASA NTRSDate not supplied

Additive Manufacturing Developments for Rocket Engines: Applications, Advanced Materials and Large Scale Techniques

Explore the source record for details and available documents.

Additive Manufacturing↗

NASA NTRS2017

Large-Scale Traveling Weather Systems in Mars Southern Extratropics

Between late fall and early spring, Mars' middle- and high-latitude atmosphere supports strong mean equator-to-pole temperature contrasts and an accompanying mean westerly polar vortex. Observations from both the MGS Thermal Emission Spectrometer (TES) and the MRO Mars Climate Sounder (MCS) indicate that a mean baroclinicity-barotropicity supports intense, large-scale eastward traveling weather systems (i.e., transient synoptic-period waves). Such extratropical weather disturbances are critical components of the global circulation as they serve as agents in the transport of heat and momentum, and generalized scalar/tracer quantities (e.g., atmospheric dust, water-vapor and ice clouds). The character of such traveling extratropical synoptic disturbances in Mars' southern hemisphere during late winter through early spring is investigated using a moderately high-resolution Mars global climate model (Mars GCM). This Mars GCM imposes interactively-lifted and radiatively-active dust based on a threshold value of the surface stress. The model exhibits a reasonable "dust cycle" (i.e., globally averaged, a dustier atmosphere during southern spring and summer occurs). Compared to the northern-hemisphere counterparts, the southern synoptic-period weather disturbances and accompanying frontal waves have smaller meridional and zonal scales, and are far less intense. Influences of the zonally asymmetric (i.e., east-west varying) topography on southern large-scale weather are investigated, in addition to large-scale up-slope/down-slope flows and the diurnal cycle. A southern storm zone in late winter and early spring presents in the western hemisphere via orographic influences from the Tharsis highlands, and the Argyre and Hellas impact basins. Geographically localized transient-wave activity diagnostics are constructed that illuminate dynamical differences amongst the simulations and these are presented.

Hollingsworth, Jeffery L.↗

NASA NTRS2019

Extratropical Large-Scale Traveling Weather Systems in the Southern Hemisphere on Mars

From late-autumn through early-spring, the middle- and high-latitudes of both hemispheres of Mars and its predominantly carbon-dioxide atmosphere support mean equator-to-pole thermal contrasts, and then, support a strong mean westerly polar vortex. Observations from orbiting spacecraft indicate that this intense mean baroclinicity-barotropicity supports large-scale eastward traveling weather systems (i.e., transient, traveling synoptic-period waves, on the order of the Rossby deformation scale). On Earth, extratropical weather disturbances arise from wind-shear instabilities, and these are critical components of the terrestrial global circulation. So it is the case for Mars. Large-scale traveling weather systems on Mars serve as agents in the transport of heat, momentum and scalar and tracer quantities (e.g., atmospheric dust, watervapor, ice clouds, chemical species, etc). Such weather systems interact with other large-scale atmospheric circulation components, namely, quasi-stationary (i.e., forced Rossby) modes; global thermal tidal modes; and then, upon large-/continental- geographical scales, upslope/ down-slope flows amongst high relief, low relief, impact basins, and volcanic rises, and more. The character of Mars' traveling extratropical weather disturbances in its southern hemisphere during late winter through early spring is investigated using a high-resolution Mars global climate model (i.e., Mars GCM), and one from the Agency's Mars Climate Modeling Center (MCMC) based at the NASA Ames Research Center. The climate model includes several complex atmospheric physical packages. With such physics modules, our global climate simulations present comparatively well with observations of the planet's current water cycle (Haberle et al.,2019). The climate model is "forced" with an annual dust cycle (i.e., nudged based on MGS/TES observations). Compared to the northern-hemisphere counterparts, the southern synoptic-period weather disturbances and accompanying frontal waves have smaller meridional and zonal scales, and are less intense. Influences of the zonally asymmetric (i.e., east-west varying) topography on southern large-scale weather are investigated, in addition to large-scale up-slope/down-slope flows and the diurnal cycle. A southern storm zone in late winter and early spring presents in the western hemisphere via orographic influences from the Tharsis highlands, and the Argyre and Hellas impact basins. Geographically localized transient-wave activity diagnostics are constructed that illuminate dynamical differences amongst the simulations and these are presented.

Hollingsworth, Jeffery L.↗

NASA NTRS2017

Refractory Organics in Comet 67P Churyumov-Gerasimenko: Additional Evidence for Large-scale Mixing in the Primitive Solar Nebula?

The COSIMA instrument onboard the Rosetta spacecraft collected and analyzed samples of individual particles from the coma of Comet67P/ Churyumov-Gerasimenko. Initial results of the analysis of several particles have been presented elsewhere while analyses of the organic component of the dust particles has been shown to compare favor ably to laboratory spectra of IOM extracted from the Orguil and Murchison meteorites. Here we will compare the spectra of the same two particles to laboratory spectra of organic grain coatings produced via Surface Mediated Reactions of CO, H2 and N2 on amorphous iron silicate grains.

Refractory Organics↗

DOE OSTI2025

The Cost of Scaling Up in Large-Format Additive Manufacturing

Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m 3 , these printers have pushed the boundaries of achievable print volume while allowing the utilization of low-cost feedstocks, such as cementitious materials and polymer pellets, like those used in injection molding. Continued workspace expansion requires an examination of the inherent trade-offs, which impact capital and operational costs. Here, in this work, the authors examine these trade-offs to determine fundamental scaling laws for existing system architectures, survey the state of the art for alternative system configurations, and pose recommendations for future system designers to continue the evolution of large-scale AM systems.

3D printing↗