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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 NTRS1988

Helicopter human factors research

Helicopter flight is among the most demanding of all human-machine integrations. The inherent manual control complexities of rotorcraft are made even more challenging by the small margin for error created in certain operations, such as nap-of-the-Earth (NOE) flight, by the proximity of the terrain. Accident data recount numerous examples of unintended conflict between helicopters and terrain and attest to the perceptual and control difficulties associated with low altitude flight tasks. Ames Research Center, in cooperation with the U.S. Army Aeroflightdynamics Directorate, has initiated an ambitious research program aimed at increasing safety margins for both civilian and military rotorcraft operations. The program is broad, fundamental, and focused on the development of scientific understandings and technological countermeasures. Research being conducted in several areas is reviewed: workload assessment, prediction, and measure validation; development of advanced displays and effective pilot/automation interfaces; identification of visual cues necessary for low-level, low-visibility flight and modeling of visual flight-path control; and pilot training.

Nagel, David C.↗
NASA NTRS2024

Optimizing Air Traffic - Integrating Artificial Intelligence and Machine Learning in Flight Path Planning and 3D Airspace Visualization for Air Traffic Control

Air Traffic Control (ATC) systems are vital components of the National Airspace System (NAS). ATC, Airport Traffic Control Towers (ATCT), and Terminal Radar Approach Control (TRACON) are responsible for directing all flights departing from and arriving at airports, managing our nation’s airspace, preventing potential accidents, and ensuring that every flight is accounted for. However, these systems often face challenges in effectively monitoring the skies. Issues such as poor communication between operators, difficulty in performing operations, and the constant need for vigilance frequently burden ATC operators. Additionally, the projected increase in air traffic in the coming years will only exacerbate the stress associated with this role. To address these issues, we propose a system that assists ATC operators in situations such as handovers, emergencies, and routing aircraft to avoid weather hazards. Our solution includes an Artificial Intelligence (AI) and Machine Learning (ML)-based Flight Pathways Planning System (FPPS) designed to find the fastest and most optimal routes for aircraft, taking into account weather conditions, restricted terrain, and Extended-Range Twin-Engine Operational Performance Standards (ETOPS) ratings. The proposed Predictive Weather Planning Model, included in FPPS, adjusts routes based on real-time and forecasted weather conditions. Additionally, our NVIDIA Omniverse 3D Visualization System offers a highly interactive environment for better visualization and a clear view of the airspace. By incorporating these systems, the roles of ATC, ATCT, and TRACON operators will become more manageable and less stressful, equipping them to efficiently handle the growing density of airspace.

Regina Ayoubi↗
NASA NTRS1988

Control of the induced microgravity environment of the Man Tended Free Flyer (MTFF)

Induced disturbance sources have been identified on board the Man Tended Free Flyer (MTFF). Vibration responses at sensitive payload/spacecraft interfaces have been predicted by the application of an empirically found spacecraft dynamic transfer function. Vibrations from fluid loops (Freon, water) and of reaction wheels are assessed to be the main contributors to the induced microgravity environment. The expected payload acceleration response amplitudes presented here are more than one hundred times higher than the admissible values given by the MTFF system requirement, not considering the structural striction-friction effects which could be avoided by appropriate design. Real responses will be significantly lower because the derivation of excitation and transmission functions are based on worst case assumptions. The results indicate that future activities must be concentrated on equipment design improvement and the implementation of vibration reduction along the disturbance transmission path. The activities must be accompanied by early equipment and assembly development tests and transmissibility measurements with the integrated spacecraft engineering and structural models in order to improve the accuracy of payload response predictions.

Schlund, Juergen↗
NASA NTRS1999

Integrated Modeling Tools for Thermal Analysis and Applications

Integrated modeling of spacecraft systems is a rapidly evolving area in which multidisciplinary models are developed to design and analyze spacecraft configurations. These models are especially important in the early design stages where rapid trades between subsystems can substantially impact design decisions. Integrated modeling is one of the cornerstones of two of NASA's planned missions in the Origins Program -- the Next Generation Space Telescope (NGST) and the Space Interferometry Mission (SIM). Common modeling tools for control design and opto-mechanical analysis have recently emerged and are becoming increasingly widely used. A discipline that has been somewhat less integrated, but is nevertheless of critical concern for high precision optical instruments, is thermal analysis and design. A major factor contributing to this mild estrangement is that the modeling philosophies and objectives for structural and thermal systems typically do not coincide. Consequently the tools that are used in these discplines suffer a degree of incompatibility, each having developed along their own evolutionary path. Although standard thermal tools have worked relatively well in the past. integration with other disciplines requires revisiting modeling assumptions and solution methods. Over the past several years we have been developing a MATLAB based integrated modeling tool called IMOS (Integrated Modeling of Optical Systems) which integrates many aspects of structural, optical, control and dynamical analysis disciplines. Recent efforts have included developing a thermal modeling and analysis capability, which is the subject of this article. Currently, the IMOS thermal suite contains steady state and transient heat equation solvers, and the ability to set up the linear conduction network from an IMOS finite element model. The IMOS code generates linear conduction elements associated with plates and beams/rods of the thermal network directly from the finite element structural model. Conductances for temperature varying materials are accommodated. This capability both streamlines the process of developing the thermal model from the finite element model, and also makes the structural and thermal models compatible in the sense that each structural node is associated with a thermal node. This is particularly useful when the purpose of the analysis is to predict structural deformations due to thermal loads. The steady state solver uses a restricted step size Newton method, and the transient solver is an adaptive step size implicit method applicable to general differential algebraic systems. Temperature dependent conductances and capacitances are accommodated by the solvers. In addition to discussing the modeling and solution methods. applications where the thermal modeling is "in the loop" with sensitivity analysis, optimization and optical performance drawn from our experiences with the Space Interferometry Mission (SIM), and the Next Generation Space Telescope (NGST) are presented.

Milman, Mark H.↗
DOE OSTI2025

Transport and confinement physics: Chapter 2 of the special issue: on the path to tokamak burning plasma operation

Progress in physics understanding and theoretical model development of plasma transport and confinement (TC) in the ITPA TC Topical Group since the publication of the ITER Physics Basis (IPB) document (Doyle et al 2007 Nucl. Fusion 47 S18) was summarized focusing on the contributions to ITER and burning plasma prediction and control. This paper provides a general and streamlined overview on the advances that were mainly led by the ITPA TC joint experiments and joint activities for the last 15 years (see JEX/JA table in appendix). This paper starts with the scientific strategy and scope of the ITPA TC Topical group and overall picture of the major progress, followed by the progress of each research field: particle transport, impurity transport, ion and electron thermal turbulent transport, momentum transport, impact of 3D magnetic fields on transport, confinement mode transitions, global confinement, and reduced transport modeling. Cross references with other Topical Groups are given in order to highlight overlapped topics, such as the 3D effect on the plasma transport in the edge and L-H transition physics. The increasing overlap between the topical groups is a reflection of the progress on integrating the known physics into comprehensive models that are better and better able to reproduce the plasma transport. In recent years, such integration has become increasingly prevalent when considering transport from the SOL, through the edge pedestal, and into the plasma core. In the near future, increased collaboration also with the magneto-hydrodynamic and energetic particles community will be important as we approach burning plasma conditions in next-step fusion devices. A summary of remaining challenges and next steps for each research field is given in the Summary section.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2025

Photophoretic Propulsion Enabling Mesosphere Exploration NIAC Phase I Final Report

This Phase I report presents a comprehensive study on photophoretic flyers—innovative, ultralight, solar-powered vehicles that harness photophoretic forces generated via Knudsen pumping to achieve sustained flight in the mesosphere (50–80 km altitude). By integrating advanced materials such as nanocardboard— characterized by its extremely low areal density (~1 g/m²) and high bending stiffness—with ultrathin light-absorbing coatings, the project converts incident solar radiation directly into a directed thrust. Extensive experimental investigations, coupled with high-fidelity computational fluid dynamics (CFD) simulations using ANSYS Fluent, validate the concept across various three-dimensional geometries, including spherical, conical, and rocket-shaped configurations. These simulations bridge the gap between free-molecular and continuum flow regimes, demonstrating that optimized designs can generate lift forces sufficient to support kilogram-scale payloads even in low-pressure environments. At the heart of this innovation is the use of Knudsen pumping, where temperature gradients across porous surfaces induce directional gas flow, creating a modest overpressure that provides lift. The report introduces an analytical framework that interpolates between the well-known low-Reynolds number drag regime and the high-Reynolds number momentum theory. This model accurately predicts lift based on design parameters such as microchannel dimensions, porous wall geometry, areal density, and nozzle exit area. For instance, simulations indicate that 10-meter-scale structures with carefully engineered porous walls can achieve the necessary pressure differential to support scientifically significant payloads (~1 kg). The study also explores a hybrid propulsion approach that combines solar buoyancy with photophoretic lift. Initially, solar heating creates a buoyant force that elevates the flyer to mesospheric altitudes. Once in the optimal pressure range, the photophoretic mechanism—powered by Knudsen pumping—takes over as the primary source of lift, ensuring stable, long-duration flight. This dual-mode operation not only facilitates the deployment of photophoretic flyers but also broadens the potential applications for mesospheric exploration. In addition to propulsion, the report investigates the integration of photophoretic thrusters for trajectory control of existing research balloons in the upper stratosphere. By dynamically adjusting the nozzle orientation and controlling the flow-through velocity, these thrusters provide precise maneuverability, enabling the flyers to counteract atmospheric disturbances and adjust their flight paths in real time. For example, a photophoretic thruster approximately 7.5 by 7.5 meters in size could be unfolded below a payload gondola of a 60 million-cubic-foot zero-pressure balloon. Such a thruster can provide horizontal speed control of approximately 1 m/s using only sunlight and no moving parts (except those needed to track the Sun and control the jet direction). Importantly, photophoretic thrusters operate more efficiently at higher altitudes, which is complementary to known trajectory control techniques, such as propellers and tethered wings, which are more effective at lower altitudes. Finally, the report identifies three scientific research thrusts where mesospheric aircraft technology can have a profound impact: atmospheric tides, characterization of gravity waves, and investigation of mesospheric instabilities. Overall, the findings of this Phase I project represent a significant advancement in photophoretic propulsion technology. By demonstrating that large-scale, ultralight structures can be powered solely by solar radiation—via carefully engineered Knudsen pumping—this work lays a robust foundation for scalable, near-space flight architectures. Future refinements in material fabrication, structural optimization, and integrated trajectory control are expected to further enhance performance, paving the way for operational demonstrations that could revolutionize atmospheric science, remote sensing, and communication networks.

Knudsen Pump↗
NASA NTRS2010

Adaptive Data-based Predictive Control for Short Take-off and Landing (STOL) Aircraft

Data-based Predictive Control is an emerging control method that stems from Model Predictive Control (MPC). MPC computes current control action based on a prediction of the system output a number of time steps into the future and is generally derived from a known model of the system. Data-based predictive control has the advantage of deriving predictive models and controller gains from input-output data. Thus, a controller can be designed from the outputs of complex simulation code or a physical system where no explicit model exists. If the output data happens to be corrupted by periodic disturbances, the designed controller will also have the built-in ability to reject these disturbances without the need to know them. When data-based predictive control is implemented online, it becomes a version of adaptive control. The characteristics of adaptive data-based predictive control are particularly appropriate for the control of nonlinear and time-varying systems, such as Short Take-off and Landing (STOL) aircraft. STOL is a capability of interest to NASA because conceptual Cruise Efficient Short Take-off and Landing (CESTOL) transport aircraft offer the ability to reduce congestion in the terminal area by utilizing existing shorter runways at airports, as well as to lower community noise by flying steep approach and climb-out patterns that reduce the noise footprint of the aircraft. In this study, adaptive data-based predictive control is implemented as an integrated flight-propulsion controller for the outer-loop control of a CESTOL-type aircraft. Results show that the controller successfully tracks velocity while attempting to maintain a constant flight path angle, using longitudinal command, thrust and flap setting as the control inputs.

Barlow, Jonathan Spencer↗
NASA NTRS1998

The Future of Air Traffic Management

A system for the control of terminal area traffic to improve productivity, referred to as the Center-TRACON Automation System (CTAS), is being developed at NASA's Ames Research Center under a joint program with the FAA. CTAS consists of a set of integrated tools that provide computer-generated advisories for en-route and terminal area controllers. The premise behind the design of CTAS has been that successful planning of traffic requires accurate trajectory prediction. Data bases consisting of representative aircraft performance models, airline preferred operational procedures and a three dimensional wind model support the trajectory prediction. The research effort has been the design of a set of automation tools that make use of this trajectory prediction capability to assist controllers in overall management of traffic. The first tool, the Traffic Management Advisor (TMA), provides the overall flow management between the en route and terminal areas. A second tool, the Final Approach Spacing Tool (FAST) provides terminal area controllers with sequence and runway advisories to allow optimal use of the runways. The TMA and FAST are now being used in daily operations at Dallas/Ft. Worth airport. Additional activities include the development of several other tools. These include: 1) the En Route Descent Advisor that assist the en route controller in issuing conflict free descents and ascents; 2) the extension of FAST to include speed and heading advisories and the Expedite Departure Path (EDP) that assists the terminal controller in management of departures; and 3) the Collaborative Arrival Planner (CAP) that will assist the airlines in operational decision making. The purpose of this presentation is to review the CTAS concept and to present the results of recent field tests. The paper will first discuss the overall concept and then discuss the status of the individual tools.

Denery, Dallas G.↗
NASA NTRS2013

Predicting Pilot Behavior in Medium Scale Scenarios Using Game Theory and Reinforcement Learning

Effective automation is critical in achieving the capacity and safety goals of the Next Generation Air Traffic System. Unfortunately creating integration and validation tools for such automation is difficult as the interactions between automation and their human counterparts is complex and unpredictable. This validation becomes even more difficult as we integrate wide-reaching technologies that affect the behavior of different decision makers in the system such as pilots, controllers and airlines. While overt short-term behavior changes can be explicitly modeled with traditional agent modeling systems, subtle behavior changes caused by the integration of new technologies may snowball into larger problems and be very hard to detect. To overcome these obstacles, we show how integration of new technologies can be validated by learning behavior models based on goals. In this framework, human participants are not modeled explicitly. Instead, their goals are modeled and through reinforcement learning their actions are predicted. The main advantage to this approach is that modeling is done within the context of the entire system allowing for accurate modeling of all participants as they interact as a whole. In addition such an approach allows for efficient trade studies and feasibility testing on a wide range of automation scenarios. The goal of this paper is to test that such an approach is feasible. To do this we implement this approach using a simple discrete-state learning system on a scenario where 50 aircraft need to self-navigate using Automatic Dependent Surveillance-Broadcast (ADS-B) information. In this scenario, we show how the approach can be used to predict the ability of pilots to adequately balance aircraft separation and fly efficient paths. We present results with several levels of complexity and airspace congestion.

Game Theory↗
NASA NTRS2002

Mountain-Top-to-Mountain-Top Optical Link Demonstration

A mountain-top-to-mountain-top optical communications demonstration was conducted between the JPL Table Mountain Facility (TMF), Wrightwood, California, and Strawberry Peak (SP), Lake Arrowhead, California, during the months of August and September of 2000. The link was nearly horizontal at an altitude of 2 km and spanned a range of 46.8 km. A 780-nm multibeam beacon broadcast from TMF was received by the JPL Optical Communications Demonstrator (OCD) located at SP. The received beacon was utilized as a pointing reference to retransmit an 852-nm communications laser beam, modulated at 400 Mb/s by a PN7 pseudo-random bit stream (PRBS) sequence. The long atmospheric path resulted in atmospheric-turbulence-induced angle-of-arrival fluctuations of the beacon at the OCD aperture. A .ne-steering control loop was used to track the resulting beacon centroid motion and update the pointing of the communications laser beam transmitted from SP to TMF. Fried parameters, or r0, inferred from focal spot sizes received at SP were 4 to 5 cm whereas, using the spot sizes received at TMF, they were 2 to 3 cm. In both cases, theory predicts larger r0 values. The predicted angle-of-arrival fluctuations compare well with measured rms displacements exhibited by the focal spots at either end of the link. An uncompensated error of ~1.1 rad in the x-axis and ~2 rad in the y-axis was obtained using centroid data logged by the OCD. Average bit-error rates of 10-5 were recorded for extended periods of time. An atmospheric coherence length r0 of 3 to 5 cm was inferred using the focal-plane spot size measured on the CCD tracking sensor and compared to a predicted value of 5 to 7 cm using reasonable atmospheric models. The irradiance bounds required for the CCD tracking sensor to perform centroiding was found to range from 2000 to 3000 integrated pixel counts, although a more reliable range was 600 to 3000, indicating a dynamic range of 6 to 11 dB. The motion of the spot on the focal plane was also recorded and yielded rms angle-of-arrival-induced focal-plane displacement of 9 to 11 m, compared to a predicted value of 7.8 to 11 m. The irradiance measurements made with the OCD clearly indicate that best tracking performance is obtained when the mean received signal is 2000 to 2200 counts. The best tracking performance resulted in an rms uncompensated error of 1.1 rad. The uncompensated error appeared to increase with either an increase or decrease in mean beacon-signal level. The rms uncompensated error determined by deriving the beacon displacement power spectral density from the beacon centroid-versustime data and the rejection function of the control loop yielded a higher value of 3.4 rad.

Biswas, A.↗
DOE OSTI2026

Integrated System Planning: Emerging Software Requirements in the Power Industry

Power system planning software remains fragmented across organizational boundaries, with specialized tools for capacity expansion, production cost modeling, power flow, and dynamic analysis operating on incompatible data models and assumptions. This article argues that the fragmentation is not merely a technical problem but a predictable consequence of Conway's law: software architectures mirror the departmental structures within which they are developed. Regulatory milestones like Federal Energy Regulatory Commission (FERC) Order 888 formalized these divisions, but the roots trace back to the distinct engineering disciplines-mechanical, chemical, and electrical-that staffed generation and transmission planning departments in vertically integrated utilities. As the industry moves toward integrated system planning (ISP) that coordinates generation, transmission, and distribution investment decisions, the software ecosystem must evolve accordingly. We identify five categories of software requirements to enable this transition: coherent data inputs decoupled from individual applications, unified and extensible data schemas, modular component representations that support multiple abstraction levels, lifecycle management of planning datasets, and well-defined application programming interface (API) contracts that separate data exchange from algorithmic control. We examine how these requirements interact with three common workflow patterns-serial gate clearing, sequential multiapplication, and convergence oriented-and discuss the interface design principles each demands. We then outline a vision for platform-based planning architectures where specialized analytical services compose through standardized interfaces and where artificial intelligence (AI)/machine learning (ML) tools augment decision support within a disciplined software infrastructure. The practices proposed here offer a path from today's siloed tool collections toward collaborative planning ecosystems capable of handling the complexity of modern power system transformation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRSDate not supplied

An Integrated Software Architecture for Solar Cruiser Mission Design and Navigation

Solar Cruiser is a solar sailing mission, riding as a secondary payload to the Interstellar Mapping and Acceleration Probe (IMAP) mission, expected to launch in February of 2025. The Solar Cruiser vehicle will generate thrust via a complex, low-thrust solar sail. The extreme low-thrust nature of the solar sail will leave Solar Cruiser highly sensitive to external environmental effects (such as solar radiation pressure and high-order gravitational perturbations) throughout the entirety of flight. Because of this, preliminary & operational optimization routines must be intricately tied to high-order predictive propagation models to ensure the greatest possible confidence in mission success. The Solar Cruiser Mission Design and Navigation (MDNav) team has designed a software tool suite, employing the latest in software containerization technology, to accomplish this task, allowing for seamless development across several users and operating systems. Combining JPL’s Monte toolkit with University of Alabama’s high-performance optimizer, ASSET, the proposed architecture allows for instant verification of optimized trajectories within the same development environment that the optimization takes place, removing the need for mission designers and navigators to switch between tools. The MDNav software suite itself is separated from the development and operational scripts to be used in flight, which allows for maintaining a low-footprint version control profile – thus avoiding unnecessary file bloating. This paper discusses the historical differences between previous iterations of the Solar Cruiser MDNav tool suite and the current iteration, planned operational interfaces of the tool with other software and subsystems, and the planned path forward in maintaining containerization services for the software throughout the lifetime of Solar Cruiser.

solar cruiser↗
NASA NTRSDate not supplied

An Integrated Software Architecture for Solar Cruiser Mission Design and Navigation

Solar Cruiser is a solar sailing mission, riding as a secondary payload to the Interstellar Mapping and Acceleration Probe (IMAP) mission, slated to launch in February of 2025. The Solar Cruiser vehicle will generate thrust via a complex, low-thrust solar sail. The extreme low-thrust nature of the solar sail will leave Solar Cruiser highly sensitive to external environmental effects (such as solar radiation pressure and high-order gravitational perturbations) throughout the entirety of flight. Because of this, preliminary operational optimization routines must be intricately tied to high-order predictive propagation models to ensure the greatest possible confidence in mission success. The Solar Cruiser Mission Design and Navigation (MDNav) team has designed a software tool suite, employing the latest in software containerization technology, to accomplish this task; allowing for seamless development across several users and operating systems. Combining JPL’s Monte toolkit with high-performance optimizers written by the University of Alabama, the proposed architecture allows for instant verification of optimized trajectories within the same development environment that the optimization takes place, removing the need for mission designers and navigators to switch between tools. The MDNav suite image deployment process is separated from the development and operational scripts to be used in flight, which allows for maintaining a low-footprint version control profile without unnecessary file bloating. This paper discusses the historical differences between previous iterations of the Solar Cruiser MDNav tool suite and the current iteration, planned operational interfaces of the tool with other software and subsystems, and the planned path forward in maintaining containerization services for the software throughout the lifetime of Solar Cruiser.

optimization↗
DOE OSTI2025

Convergent Manufacturing of Large-Scale Components for Nuclear Applications, via Additive Manufacturing and Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy (PM)–hot isostatic pressing (PM-HIP) has long been recognized as a powerful route for producing fully dense, near net shape metallic components. By consolidating powders under high temperature and pressure, HIP provides isotropic properties, uniform microstructures, and scalability to complex geometries that are vital for sectors such as aerospace, energy, and nuclear power. Yet despite these advantages, the technology has remained constrained by costly trial and error canister fabrication, limitations of conventional forging, and incomplete knowledge about how the canister design influences final part properties. Additive manufacturing (AM), by contrast, thrives on design freedom and geometric flexibility but struggles with speed, scalability, and cost when applied to very large structures. The research presented in this report investigated how a convergent manufacturing approach, combining AM with PM-HIP, can merge the strengths of both technologies, leveraging AM’s flexibility for canister design and HIP’s consolidation capability to deliver reliable, large, and complex parts. The work progressed through three case studies that built on one another in scale and complexity. Small cylindrical canisters fabricated by conventional methods, laser powder bed fusion, and directed energy deposition were filled with stainless steel powders and subjected to HIP. The resulting parts demonstrated near-full density and mechanical properties on par with wrought stainless steel, showing for the first time that AM canisters can be a direct substitute for conventional ones without sacrificing quality. The next step involved a medium-scale, noncentrosymmetric T-valve, which is an enclosed, multibranch geometry that tested the limits of AM + PM-HIP integration. The T-valve achieved predictable shrinkage and uniform densification, confirming feasibility for enclosed designs. However, this study also revealed oxide inclusions and interfacial challenges at the AM + HIP boundary, underscoring the critical importance of controlling interface chemistry and employing robust, in situ strategies, such as melt pool monitoring and thermal monitoring, coupled with nondestructive evaluation techniques such as x-ray computed tomography. Finally, the effort culminated in fabricating a large-scale impeller weighing nearly 2000 lb and spanning 5 ft in diameter. Produced via multirobot wire arc AM and hot isostatic pressed to near-full density, the impeller validated industrial-scale feasibility. Predictive models closely matched experimental shrinkage, tensile properties were spatially uniform across the component, and the AM + PM-HIP interface proved mechanically sound despite the presence of oxide-decorated prior particle boundaries. This large-scale demonstration is a major milestone, showing that hybrid AM + PM‑HIP can reliably deliver components at reactor-relevant scales. Collectively, these studies charted a logical pathway: small-scale work built scientific confidence, medium-scale work highlighted opportunities and challenges, and large-scale work proved industrial impact. The overarching conclusion of this report is that AM + PM-HIP should not be seen as a replacement for forging but as a complementary pathway that provides the US with flexibility, resilience, and new options for manufacturing nuclear-grade components. Looking ahead, several directions emerge as critical to sustaining progress. Predictive modeling must become faster, more accessible, and more accurate, with digital twins and machine learning reducing reliance on trial and error. Powders and alloys must be optimized for HIP, with improved cleanliness, reduced oxides, and tailored chemistries that enhance creep, fatigue, and irradiation resistance. Interfaces between AM and HIP regions must be better engineered through coatings, machining strategies, and surface treatments to mitigate oxide formation and ensure reliable bonding to explore opportunities for HIP of targeted compositional parts, as well as multimaterial HIP cladding applications. Monitoring and nondestructive evaluation need to expand, incorporating multimodal sensors, x-ray computed tomography, and real-time data integration through platforms such as Pelican. At the same time, the pathway to industrial adoption requires techno-economic analysis, machinability studies, and qualification frameworks aligned with industry and regulatory standards. Finally, workforce and academic engagement must be strengthened. Programs that train technicians and engineers for US Navy and US Department of Energy manufacturing challenges should be paired with academic partnerships to support fundamental research, with open sharing of non-export-controlled data to accelerate innovation and build the next generation of experts. In conclusion, this report demonstrates that hybrid AM + PM-HIP is scientifically viable and strategically important. By combining the design agility of AM with the consolidation strength of HIP and embedding modeling, monitoring, and workforce development, this approach provided a transformative new capability for US manufacturing. The path forward is clear: hybrid AM + PM-HIP is not just a promising research direction but is also potentially an industrially relevant pathway that can reshape how nuclear-grade components are designed, qualified, and deployed.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

An Integrated Software Architecture for Solar Cruiser Mission Design and Navigation

Solar Cruiser is a solar sailing mission, riding as a secondary payload to the Interstellar Mapping and Acceleration Probe (IMAP) mission, expected to launch in February of 2025. The Solar Cruiser vehicle will generate thrust via a complex, low-thrust solar sail. The extreme low-thrust nature of the solar sail will leave Solar Cruiser highly sensitive to external environmental effects (such as solar radiation pressure and high-order gravitational perturbations) throughout the entirety of flight. Because of this, preliminary & operational optimization routines must be intricately tied to high-order predictive propagation models to ensure the greatest possible confidence in mission success. The Solar Cruiser Mission Design and Navigation (MDNav) team has designed a software tool suite, employing the latest in software containerization technology, to accomplish this task, allowing for seamless development across several users and operating systems. Combining JPL’s Monte toolkit with high-performance optimizers written by researchers at the University of Alabama, the proposed architecture allows for instant verification of optimized trajectories within the same development environment that the optimization takes place, removing the need for mission designers and navigators to switch between tools. The MDNav software suite itself is separated from the development and operational scripts to be used in flight, which allows for maintaining a low-footprint version control profile – thus avoiding unnecessary file bloating. This paper discusses the historical differences between previous iterations of the Solar Cruiser MDNav tool suite and the current iteration, planned operational interfaces of the tool with other software and subsystems, and the planned path forward in maintaining containerization services for the software throughout the lifetime of Solar Cruiser.

Containerization↗
DOE OSTI2025

Toward Drilling the Perfect Geothermal Well: An International Research Coordination Network for Geothermal Drilling Optimization Supported by Deep Machine Learning and Cloud Based Data Aggregation

The EDGE project, supported by the U.S. Department of Energy Geothermal Technologies Office under award DE-EE0008793, established a data-driven framework for improving the efficiency, cost-effectiveness, and reliability of geothermal well drilling. The project focused on developing scalable data infrastructure, advanced machine learning and probabilistic models, and integrated analytics tools to support continuous drilling optimization. A central objective was to reduce geothermal drilling costs by up to seventy percent while minimizing the risk of well failure through predictive diagnostics and adaptive planning. Over the project period, a comprehensive data repository was designed and deployed, incorporating records from over one hundred geothermal wells across varied geological settings. This repository supported both structured and unstructured data and adhered to FAIR data principles, enabling provenance tracking, quality control, and standardized metadata. The project introduced automated ingestion pipelines and a cloud-hosted platform that facilitated access to raw, processed, and derived datasets. This infrastructure served as the foundation for model development and analysis. Machine learning workflows were developed to predict key drilling metrics including rate of penetration, non-productive time, and total drilling costs. Self-organizing maps and dimensionality reduction methods were used to uncover operational patterns and outliers, while supervised learning algorithms such as random forests and deep neural networks were applied to forecast performance outcomes. The models were validated on heterogeneous datasets from both U.S. and Icelandic fields, demonstrating variable but significant predictive accuracy. The results indicated that finer temporal resolution, inclusion of lithological data, and consistency in operational annotations could substantially improve model performance. The project also implemented process mining techniques to reconstruct state-transition models from drilling event logs. These models enabled the identification of deviations from optimal workflows and provided insights into recurring failure modes. Analysis of non-productive time highlighted the impact of equipment failures, geological challenges, and human factors, offering opportunities for targeted mitigation strategies. The EDGE Dashboard was developed as a web-based expert system integrating data visualization, model outputs, and user-driven queries. It provided an accessible interface for operators to explore historical data, evaluate predicted outcomes, and compare drilling scenarios. Initial feedback from project partners suggested that the dashboard could serve as a foundation for more advanced advisory and optimization tools. Overall, the EDGE project demonstrated the feasibility and value of applying modern data science techniques to geothermal drilling. It delivered a set of interoperable tools and models that can support more efficient, lower-risk well development. The findings point toward a viable path for transitioning from advisory analytics to semi-autonomous drilling systems, contingent on continued collaboration, expanded datasets, and field validation. The project results have immediate relevance for drilling operations, data management practices, and future geothermal R&D efforts aimed at achieving reliable, cost-competitive geothermal energy at scale.

15 GEOTHERMAL ENERGY↗
NASA NTRS2010

Physics-Based Methods of Failure Analysis and Diagnostics in Human Space Flight

The Integrated Health Management (IHM) for the future aerospace systems requires to interface models of multiple subsystems in an efficient and accurate information environment at the earlier stages of system design. The complexity of modern aeronautic and aircraft systems (including e.g. the power distribution, flight control, solid and liquid motors) dictates employment of hybrid models and high-level reasoners for analysing mixed continuous and discrete information flow involving multiple modes of operation in uncertain environments, unknown state variables, heterogeneous software and hardware components. To provide the information link between key design/performance parameters and high-level reasoners we rely on development of multi-physics performance models, distributed sensors networks, and fault diagnostic and prognostic (FD&P) technologies in close collaboration with system designers. The main challenges of our research are related to the in-flight assessment of the structural stability, engine performance, and trajectory control. The main goal is to develop an intelligent IHM that not only enhances components and system reliability, but also provides a post-flight feedback helping to optimize design of the next generation of aerospace systems. Our efforts are concentrated on several directions of the research. One of the key components of our strategy is an innovative approach to the diagnostics/prognostics based on the real time dynamical inference (DI) technologies extended to encompass hybrid systems with hidden state trajectories. The major investments are into the multiphysics performance modelling that provides an access of the FD&P technologies to the main performance parameters of e.g. solid and liquid rocket motors and composite materials of the nozzle and case. Some of the recent results of our research are discussed in this chapter. We begin by introducing the problem of dynamical inference of stochastic nonlinear models and reviewing earlier results. Next, we present our analytical approach to the solution of this problem based on the path integral formulation. The resulting algorithm does not require an extensive global search for the model parameters, provides optimal compensation for the effects of dynamical noise, and is robust for a broad range of dynamical models. In the following Section the strengths of the algorithm are illustrated illustrated by inferring the parameters of the stochastic Lorenz system and comparing the results with those of earlier research. Next, we discuss a number of recent results in application to the development of the IHM for aerospace system. Firstly, we apply dynamical inference approach to a solution of classical three tank problems with mixed unknown continuous and binary parameters. The problem is considered in the context of ground support system for filling fuel tanks of liquid rocket motors. It is shown that the DI algorithm is well suited for successful solution of a hybrid version of this benchmark problem even in the presence of additional periodic and stochastic perturbation of unknown strength. Secondly, we illustrate our approach by its application to an analysis of the nozzle fault in a solid rocket motor (SRM). The internal ballistics of the SRM is modelled as a set of one-dimensional partial differential equations coupled to the dynamics of the propellant regression. In this example we are specifically focussed on the inference of discrete and continuous parameters of the nozzle blocking fault and on the possibility of an application of the DI algorithm to reducing the probability of "misses" of an on-board FD&P for SRM. In the next section re-contact problem caused by first stage/upper stage separation failure is discussed. The reaction forces imposed on the nozzle of the upper stage during the re-contact and their connection to the nozzle damage and to the thrust vector control (TVC) signal are obtained. It is shown that transient impact induced torquean be modelled as a response of an effective damped oscillator. A possible application of the DI algorithm to the inference of damage parameters and predicting fault dynamics ahead of time using the actuator signal is discussed. Finally, we formulate Bayesian inferential framework for development of the IHM system for in-flight structural health monitoring (SHM) of composite materials. We consider the signal generated by piezoelectric actuator mounted on composite structure generating elastic waves in it. The signal received by the sensor is than compared with the baseline signal. The possibility of damage inference is discussed in the context of development of the SHM.

Smelyanskiy, Vadim N.↗
DOE OSTI2025

Hierarchical Speed Planner for Automated Vehicles: A Framework for Lagrangian Variable Speed Limit in Mixed-Autonomy Traffic

Here, this article presents a novel hierarchical speed planning framework for variable speed limits in mixed-autonomy traffic environments, leveraging server-side macroscopic control and vehicle-side microscopic execution. The framework integrates real-time traffic state estimation (TSE) and reinforcement learning (RL)-based control to mitigate congestion and improve traffic flow. A TSE enhancement module combines macroscopic data from sources like INRIX with high-resolution observations from connected autonomous vehicles (CAVs), enabling predictive modeling to address latency and noise. The target speed design module employs kernel smoothing and a buffer zone strategy to optimize traffic density and flow around bottlenecks. The proposed system was validated in the largest open-road test to date with 100 CAVs, demonstrating an overall 8% traffic density decrease, with a specific decrease of 7% upstream, 10% downstream, and a 52% decrease during the congestion formation phase at bottlenecks.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗