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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Effect of Networking Density on the Patterning Performance of Molecular Layer Deposited Alucone Electron Beam/EUV Resists

One of the main barriers to continued device scaling in the era of extreme ultraviolet (EUV) lithography is the need for improved photoresist chemistries to address challenges such as poor EUV sensitivity, inadequate etch resistance, and pattern collapse. Metal-organic photoresists are a promising class of materials that can address many of these challenges, and among them, resists deposited via hybrid molecular layer deposition (MLD) have attracted interest for their unique advantages in thickness control, chemical homogeneity, and compatibility with vacuum processing. However, despite many successful demonstrations of patterning, little is known about how the molecular design of hybrid MLD resists affects their lithographic performance. In this work, we study the effect of the network structure, a common feature among all hybrid MLD resists, via a series of aluminum alkoxide ("alucone") negative tone resists with varying networking density. Their patterning mechanism is investigated via electron beam lithography (EBL)─a common proxy for EUV─and compared to their EUV-induced reactions studied via flood exposure and in situ characterization. In conclusion, we show that the resist with the least networking density demonstrates the best sensitivity and resolution, with the ability to resolve dense line/space gratings as small as 14 nm half pitch via EBL.

electron beam lithography↗
NASA NTRS1993

Single element injector cold flow testing for STME swirl coaxial injector element design

An oxidizer-swirled coaxial element injector is being investigated for application in the Space Transportation Main Engine (STME). Single element cold flow experiments were conducted to provide characterization of the STME injector element for future analysis, design, and optimization. All tests were conducted to quiescent, ambient backpressure conditions. Spray angle, circumferential spray uniformity, dropsize, and dropsize distribution were measured in water-only and water/nitrogen flows. Rupe mixing efficiency was measured using water/sucrose solution flows with a large grid patternator for simple comparative evaluation of mixing. Factorial designs of experiment were used for statistical evaluation of injector geometrical design features and propellant flow conditions on mixing and atomization. Increasing the free swirl angle of the liquid oxidizer had the greatest influence on increasing the mixing efficiency. The addition of gas assistance had the most significant effect on reducing oxidizer droplet size parameters and increasing droplet size distribution. Increasing the oxidizer injection velocity had the greatest influence for reducing oxidizer droplet size parameters and increasing size distribution for non-gas assisted flows. Single element and multi-element subscale hot fire testing are recommended to verify optimized designs before committing to the STME design.

Hulka, J.↗
NASA NTRS2016

Multilayer Active Shell Mirrors for Space Telescopes

A novel active mirror technology based on carbon fiber reinforced polymer (CFRP) substrates and replication techniques has been developed. Multiple additional layers are implemented into the design serving various functions. Nanolaminate metal films are used to provide a high quality reflective front surface. A backing layer of thin active material is implemented to provide the surface-parallel actuation scheme. Printed electronics are used to create a custom electrode pattern and flexible routing layer. Mirrors of this design are thin (< 1.0 mm), lightweight (2.7 kg/m2 ), and have large actuation capabilities. These capabilities, along with the associated manufacturing processes, represent a significant change in design compared to traditional optics. Such mirrors could be used as lightweight primaries for small CubeSat-based telescopes or as meter-class segments for future large aperture observatories. Multiple mirrors can be produced under identical conditions enabling a substantial reduction in manufacturing cost and complexity. An overview of the mirror design and manufacturing processes is presented. Predictions on the actuation performance have been made through finite element simulations demonstrating correct abilities on the order of 250−300× for astigmatic modes with only 41 independent actuators. A description of the custom metrology system used to characterize the active mirrors is also presented. The system is based on a Reverse Hartmann test and can accommodate extremely large deviations in mirror figure (> 100 µm PV) down to sub-micron precision. The system has been validated against several traditional techniques including photogrammetry and interferometry. The mirror performance has been characterized using this system, as well as closed-loop figure correction experiments on 150 mm dia. prototypes. The mirrors have demonstrated post-correction figure accuracies of 200 nm RMS (two dead actuators limiting performance).

Reverse Hartmann↗
DOE OSTI2026

HARMONY: Large-Scale Architecture Search for Efficient Hybrid Language Models

As large language models scale to trillions of parameters, their computational and memory requirements present critical challenges for efficient training and deployment. While Mixture of Experts (MoE) architectures enable efficient scaling through sparse parameter activation, and state-space models like Mamba offer linear-time complexity, principled methods for combining these paradigms remain undeveloped. We introduce HARMONY (Hybrid Architecture Research for Mamba, Optimized with Neural efficiencY), a multi-objective evolutionary neural architecture search framework for discovering efficient hybrid language models that integrate Transformer attention mechanisms, Mixture-of-Experts routing, and Mamba state-space components. Through large-scale distributed search using 16,384 MI250X GPUs on the Frontier supercomputer, HARMONY explores a comprehensive design space encompassing six attention variants (MHA, MQA, GQA, MLA, SWA, and Mamba-2), variable MoE configurations with both routed and shared experts, and extensive Mamba hyperparameters. Our framework discovers heterogeneous architectures that balance training performance with computational efficiency through multi-objective optimization incorporating latency penalties and fitness-based selection. Analysis of discovered architectures reveals that optimal hybrid designs favor heterogeneous component mixing rather than homogeneous patterns, with Mamba-2 and Multi-Head Latent Attention (MLA) emerging as preferred mechanisms. Discovered architectures demonstrate superior training efficiency: our best configuration achieves a final perplexity of 1.0874 with 2.38B parameters while processing 4,320 tokens/second, outperforming significantly larger manually designed models. Full-scale evaluation shows HARMONY's top architectures achieve better loss trajectories than equivalently-sized models using state-of-the-art configurations including Mixtral, Jamba, and Samba. Additionally, we demonstrate 91% weak scaling efficiency when training discovered 36B-parameter models across 1,024 GPUs. HARMONY is released as an open framework with comprehensive tools for building and training hybrid models using expert-data-pipeline parallelism, democratizing access to automated architecture design for next-generation language models.

Herron, Emily [ORNL] (ORCID:0000000273008172)↗
DOE OSTI2025

Investigating the Impact of Temporal and Directional Traffic Distribution on Crash Frequencies

Safety Performance Functions (SPFs) are mathematical models that establish relationships between the frequency of various crash types and site-specific characteristics, serving as essential tools for traffic safety analysis and roadway design. Traditional SPFs, however, often overlook the temporal fluctuations in traffic flow (such as peak-hour surges) and directional imbalances between opposing traffic streams. These traffic patterns can exacerbate congestion, disrupt driver behavior, and create unexpected conflict points, potentially leading to increased crash frequencies and more severe accidents. In light of this gap, this study aims to explore the potential of incorporating K-factors (representing peak-hour traffic proportions) and D-factors (reflecting the imbalance of directional traffic) into the development of SPFs to assess whether these factors can effectively represent the impact of temporal and spatial traffic distribution on roadway safety. Using crash data from Pennsylvania urban-suburban collector roadways, it is found that the D-factor plays a significant role in predicting the frequency of total crashes, fatal + injury crashes, and angle crashes, with positive coefficient signs indicating that higher directional imbalances correspond to increased crash risks. Similarly, the K-factor emerges as a critical predictor for fatal + injury crashes and rear-end crashes, with negative coefficients suggesting that a more pronounced traffic peak is associated with a reduction in expected crash frequencies. These results highlight the importance of accounting for uneven traffic distribution in both time and direction when developing SPFs, offering deeper insights into crash patterns and supporting more effective safety interventions and roadway designs.

Xu, Guanhao [ORNL] (ORCID:0000000214326357)↗
NASA NTRS2016

The Flux-Anomaly-Forced Model Intercomparison Project (FAFMIP) Contribution to CMIP6: Investigation of Sea-Level and Ocean Climate Change in Response to CO2 Forcing

The Flux-Anomaly-Forced Model Intercomparison Project (FAFMIP) aims to investigate the spread in simulations of sea-level and ocean climate change in response to CO2 forcing by atmosphere-ocean general circulation models (AOGCMs). It is particularly motivated by the uncertainties in projections of ocean heat uptake, global-mean sealevel rise due to thermal expansion and the geographical patterns of sea-level change due to ocean density and circulation change. FAFMIP has three tier-1 experiments, in which prescribed surface flux perturbations of momentum, heat and freshwater respectively are applied to the ocean in separate AOGCM simulations. All other conditions are as in the pre-industrial control. The prescribed fields are typical of pattern and magnitude of changes in these fluxes projected by AOGCMs for doubled CO2 concentration. Five groups have tested the experimental design with existing AOGCMs. Their results show diversity in the pattern and magnitude of changes, with some common qualitative features. Heat and water flux perturbation cause the dipole in sea-level change in the North Atlantic, while momentum and heat flux perturbation cause the gradient across the Antarctic Circumpolar Current. The Atlantic meridional overturning circulation (AMOC) declines in response to the heat flux perturbation, and there is a strong positive feedback on this effect due to the consequent cooling of sea-surface temperature in the North Atlantic, which enhances the local heat input to the ocean. The momentum and water flux perturbations do not substantially affect the AMOC. Heat is taken up largely as a passive tracer in the Southern Ocean, which is the region of greatest heat input, while the weakening of the AMOC causes redistribution of heat towards lower latitudes. Future analysis of these and other phenomena with the wider range of CMIP6 FAFMIP AOGCMs will benefit from new diagnostics of temperature and salinity tendencies, which will enable investigation of the model spread in behaviour in terms of physical processes as formulated in the models.

thermosteric sea-level change↗
NASA NTRS1976

The design and fabrication of microstrip omnidirectional array antennas for aerospace applications

A microstrip antenna design concept was developed that will provide quasi-omnidirectional radiation pattern characteristics about cylindrical and conical aerospace structures. L-band and S-band antenna arrays were designed, fabricated, and, in some cases, flight tested for rocket, satellite, and aircraft drone applications. Each type of array design is discussed along with a thermal cover design that was required for the sounding rocket applications.

Campbell, T. G.↗
NASA NTRS1977

C-MOS bulk metal design handbook

The LSI standard cell array technique was used in the fabrication of more than 20 CMOS custom arrays. This technique consists of a series of computer programs and design automation techniques referred to as the Computer Aided Design And Test (CADAT) system that automatically translate a partitioned logic diagram into a set of instructions for driving an automatic plotter which generates precision mask artwork for complex LSI arrays of CMOS standard cells. The standard cell concept for producing LSI arrays begins with the design, layout, and validation of a group of custom circuits called standard cells. Once validated, these cells are given identification or pattern numbers and are permanently stored. To use one of these cells in a logic design, the user calls for the desired cell by pattern number. The Place, Route in Two Dimension (PR2D) computer program is then used to automatically generate the metalization and/or tunnels to interconnect the standard cells into the required function. Data sheets that describe the function, artwork, and performance of each of the standard cells, the general procedure for implementation of logic in CMOS standard cells, and additional detailed design information are presented.

Edge, T. M.↗
NASA NTRS1985

Thin film module development

The design of ARCO Solar, Inc.'s Genesis G100 photovoltaic module was driven by several criteria, including environmental stability (both electrical and mechanical), consumer aesthetics, low materials costs, and manufacturing ease. The module circuitry is designed as a 12 volt battery charger, using monolithic patterning techniques on a glass superstrate. This patterning and interconnect method proves amenable to high volume, low cost production throughput, and the use of glass serves the dual role of handling ease and availability. The mechanical design of the module centers on environmental stability. Packaging of the glass superstrate circuit must provide good resistance to thermal and humidity exposure along with hi-pot insulation and hailstone impact resistance. The options considered are given. Ethylene vinyl acetate (EVA) is chosen as the pottant material for its excellent weatherability.

Jester, T.↗
NASA NTRS2013

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗
NASA NTRS1982

Wing flap-type control effectiveness and effects of control hinge gap seals for a supercritical wing

Wind-tunnel tests were made to investigate the control effectiveness of wing trailing-edge flap-type aerodynamic controls for a supercritical wing. The tests determined the effects of spanwise flap control location, two different wing transition grit location patterns, magnitude of angular control deflection, control hinge moments and control hinge gap seals. Results show that the inboard flap position deflections caused interference rearward at the vertical tail, and that all flap positions for deflections in one direction only caused interference at the horizontal tail at a higher than design Mach number. Changes in wing transition grit pattern caused significant changes to static longitudinal characteristics and longitudinal control effectiveness.

Anglin, E. L.↗
NASA NTRS2009

Microstrip Antenna for Remote Sensing of Soil Moisture and Sea Surface Salinity

This compact, lightweight, dual-frequency antenna feed developed for future soil moisture and sea surface salinity (SSS) missions can benefit future soil and ocean studies by lowering mass, volume, and cost of the antenna system. It also allows for airborne soil moisture and salinity remote sensors operating on small aircraft. While microstrip antenna technology has been developed for radio communications, it has yet to be applied to combined radar and radiometer for Earth remote sensing. The antenna feed provides a key instrument element enabling high-resolution radiometric observations with large, deployable antennas. The design is based on the microstrip stacked-patch array (MSPA) used to feed a large, lightweight, deployable, rotating mesh antenna for spaceborne L-band (approximately equal to 1 GHz) passive and active sensing systems. The array consists of stacked patches to provide dual-frequency capability and suitable radiation patterns. The stacked-patch microstrip element was designed to cover the required L-band center frequencies at 1.26 GHz (lower patch) and 1.413 GHz (upper patch), with dual-linear polarization capabilities. The dimension of patches produces the required frequencies. To achieve excellent polarization isolation and control of antenna sidelobes for the MSPA, the orientation of each stacked-patch element within the array is optimized to reduce the cross-polarization. A specialized feed-distribution network was designed to achieve the required excitation amplitude and phase for each stacked-patch element.

Ramhat-Samii, Yahya↗
NASA NTRS1997

Optical Verification Laboratory Demonstration System for High Security Identification Cards

Document fraud including unauthorized duplication of identification cards and credit cards is a serious problem facing the government, banks, businesses, and consumers. In addition, counterfeit products such as computer chips, and compact discs, are arriving on our shores in great numbers. With the rapid advances in computers, CCD technology, image processing hardware and software, printers, scanners, and copiers, it is becoming increasingly easy to reproduce pictures, logos, symbols, paper currency, or patterns. These problems have stimulated an interest in research, development and publications in security technology. Some ID cards, credit cards and passports currently use holograms as a security measure to thwart copying. The holograms are inspected by the human eye. In theory, the hologram cannot be reproduced by an unauthorized person using commercially-available optical components; in practice, however, technology has advanced to the point where the holographic image can be acquired from a credit card-photographed or captured with by a CCD camera-and a new hologram synthesized using commercially-available optical components or hologram-producing equipment. Therefore, a pattern that can be read by a conventional light source and a CCD camera can be reproduced. An optical security and anti-copying device that provides significant security improvements over existing security technology was demonstrated. The system can be applied for security verification of credit cards, passports, and other IDs so that they cannot easily be reproduced. We have used a new scheme of complex phase/amplitude patterns that cannot be seen and cannot be copied by an intensity-sensitive detector such as a CCD camera. A random phase mask is bonded to a primary identification pattern which could also be phase encoded. The pattern could be a fingerprint, a picture of a face, or a signature. The proposed optical processing device is designed to identify both the random phase mask and the primary pattern [1-3]. We have demonstrated experimentally an optical processor for security verification of objects, products, and persons. This demonstration is very important to encourage industries to consider the proposed system for research and development.

Javidi, Bahram↗
NASA NTRS2018

Evaluation of a Variable Thickness Hybrid Composite Bull Gear

For several years, NASA Glenn Research Center and the U.S. Army Research Laboratory have been investigating hybrid (compositesteel) gear technology for use in vertical lift drive systems. The hybrid gear concept replaces the structural portion of a gear between the shaft and the gear rim with a lightweight carbon fiber composite, in an effort to reduce the overall weight of a gear and increase the drive system power density. An overview of the concept of the hybrid gear design is described in Ref. 1, 2, and 3. The research presented in these references includes both small-scale and large-scale hybrid gear concepts all of which have a constant composite thickness throughout. The design described in this paper is of a variable thickness, such that the composite is thickest at the inner diameter and this thickness is gradually reduced toward the outer diameter. The resulting stair stepped design stems from dropping plies of the braided carbon fiber composite fabric gradually with increased radius. Additionally, the interlock pattern at the inner metallic adapter was adjusted slightly from previous designs to obtain a better stress distribution on the inner metallic adapter. The manufactured variable thickness web was tested both in static torsion tests and operationally in a relevant gearbox environment. The results of these experiments will be presented and compared to a baseline steel configuration.

Rotorcraft Propulsion↗
NASA NTRS1989

Optical Firmware

Data-processing system exploits high speeds inherent in optical elements. Instruction sets for different computer operations reside on different external memory chips. Laser diodes activated for each operation generate light, reflected by holographic optical element to designated receptors in arithmetic and logic unit. Pattern of light beams embodies instruction set at given instant. With potential ability to reprogram in real time, conceptual system applicable to task-driven programming or artificial intelligence.

Bergman, Larry A.↗