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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 433 records · Page 24

Aerodynamic Data Fusion Toward the Digital Twin Paradigm

This paper considers the fusion of two aerodynamic data sets originating from differing types of physical or computer experiments. This paper specifically addresses the fusion of 1) noisy and in-complete fields from wind-tunnel measurements and 2) deterministic but biased fields from numerical simulations. These two data sources are fused in order to estimate the true field that best matches measured quantities that serve as the ground truth. For example, two sources of pressure fields about an aircraft are fused based on measured forces and moments from a wind-tunnel experiment. A fundamental challenge in this problem is that the true field is unknown and cannot be estimated with 100% certainty. A Bayesian framework is employed to infer the true fields conditioned on measured quantities of interest; essentially a statistical correction to the data is performed. The fused data may then be used to construct more accurate surrogate models suitable for early stages of aerospace design. An extension of the proper orthogonal decomposition with constraints is also introduced to solve the same problem. In this work, both methods are demonstrated on fusing the pressure distributions for flow past the RAE2822 airfoil and the Common Research Model wing at transonic conditions. Comparison of both methods reveals that the Bayesian method is more robust when data are scarce and capable of also accounting for uncertainties in the data. Furthermore, given adequate data, the proper-orthogonal-decomposition-based and Bayesian approaches lead to surprisingly similar results.

42 ENGINEERING↗

In-Situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, we report an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.

42 ENGINEERING↗

Model Based Mission Assurance in a Model Based Systems Engineering (MBSE) Framework: State-of-the-Art Assessment

This report explores the current state of the art of Safety and Mission Assurance (S&MA) in projects that have shifted towards Model Based Systems Engineering (MBSE). Its goal is to provide insight into how NASA’s Office of Safety and Mission Assurance (OSMA) should respond to this shift. In MBSE, systems engineering information is organized and represented in models: rigorous computer-based representations, which collectively make many activities easier to perform, less error prone, and scalable. S&MA practices must shift accordingly. The “Objective Structure Hierarchies” recently developed by OSMA provide the framework for understanding this shift. Although the objectives themselves will remain constant, S&MA practices (activities, processes, tools) to achieve them are subject to change. This report presents insights derived from literature studies and interviews. The literature studies gleaned assurance implications from reports of space-related applications of MBSE. The interviews with knowledgeable S&MA and MBSE personnel discovered concerns and ideas for how assurance may adapt. Preliminary findings and observations are presented on the state of practice of S&MA with respect to MBSE, how it is already changing, and how it is likely to change further. Finally, recommendations are provided on how to foster the evolution of S&MA to best fit with MBSE.

Aerospace engineering↗

Jet Propulsion Laboratory: Annual Report 2009

2009 was truly the year of astronomy at the Jet Propulsion Laboratory. While the world at large was celebrating the International Year of Astronomy, we were sending more telescopes into space than in any other year, ever. As these missions unfold, the astronomers are sure to change the way we see the universe. One of the newly lofted observatories is on a quest to find planets like our own Earth orbiting other stars. Another is a telescope that gathers infrared light to help discover objects ranging from near-Earth asteroids to galaxies in the deepest universe. We also contributed critical enabling technologies to yet two other telescopes sent into space by our partners in Europe. And astronauts returned to Earth with a JPL-built camera that had captured the Hubble Space Telescope's most memorable pictures over many years. And while it was an epic time for these missions, we were no less busy in our other research specialties. Earth's moon drew much attention from our scientists and engineers, with two JPL instruments riding on lunar orbiters; previously unseen views of shadowed craters were provided by radar imaging conducted with the giant dish antennas of the Deep Space Network, our worldwide communication portal to spacecraft around the solar system. At Mars, our rovers and orbiters were highly productive, as were missions targeting Saturn, comets and the asteroid belt. Here at our home planet, satellites and instruments continued to serve up important information on global climate change. But our main business is, of course, exploring. Many initiatives will keep us busy for years. In 2009, NASA gave approval to start planning a major flagship mission to Jupiter's moon Europa in search of conditions that could host life, working with our partners in Europe. In addition to our prospective Earth science projects, we have full slates of missions in Mars exploration, planetary exploration and space-based astronomy. This year's annual report continues our recent direction of recounting the Laboratory's accomplishments throughout the year month by month.

Jet Propulsion Laboratory (JPL)↗

Jet Propulsion Laboratory: Annual Report 2004

Once or twice in an age, a year comes along that the historians proclaim as an Annus Mirabilis - a year of wonders. For the Jet Propulsion Laboratory, 2004 was just that sort of time. From beginning to end, it was a nonstop experience of wondrous events in space. Imagine that two robot rovers embark on cross-country rambles across Mars, scrutinizing rocks for signs of past water on the now-arid world. A flagship spacecraft brakes into orbit at Saturn to begin longterm surveillance of the ringed world, preparing to drop a sophisticated probe to the surface of its haze-shrouded largest moon. Another craft makes the closest-ever pass by the nucleus of a comet, collecting sample particles as it goes. Two new space telescopes peer into the depths of the universe far beyond our solar system, viewing stars, nebulas and galaxies in invisible light beyond the spectrum our eyes can see. A pair of instruments is lofted on a NASA Earth-orbiting satellite to monitor air quality and the protective layer of ozone blanketing our home planet. A small probe brings samples of the solar wind to Earth for in-depth study. While JPL was absorbed with all of these ventures on other worlds, NASA and the White House unveiled an ambitious new plan of space exploration. The Vision for Space Exploration announced in January foresees a program of robotic and astronaut missions leading to a human return to the Moon by 2020, and eventual crewed expeditions to Mars. The vision also calls for more robotic missions to the moons of the outer planets; spaceborne observatories that will search for Earth-like planets around other stars and explore the formation and evolution of the universe; and continued study of our home planet. In order to accomplish all of this, NASA must perfect many as-yet-uninvented technologies and space transportation capabilities. JPL has a great deal to bring to this vision. Robotic exploration of Mars will lead the way for missions that will carry women and men to the red planet. Our engineers and scientists are formulating spacecraft that could use nuclear power to enable exploration missions of the future. And even now we are designing formations of space telescopes that will capture family portraits of the planets around neighboring stars. Those are only some of the ways that the Laboratory is contributing to NASA's broader goals. During 2004, JPL made a distinctive contribution to agencywide initiatives in areas such as safety, NASA transformation, the agency's Internet portal and NASA's Explorer Schools programs. Years like 2004 pose a special challenge for us. It would be easy to say that this was a once-in-a-decade high point of mission activities, but I believe that this would miss an opportunity. We are fortunate to have many space projects in the works that have the promise of being just as exhilarating as the great mission successes that we celebrated this year. The challenge and opportunity for us now is to make every year like this one.

National Aeronautics and Space Administration (NAS↗

Impact Simulation of Composite Panels for Aerospace Applications

The aerospace research community has been working towards the development of a comprehensive framework for the design of composite structures at the component, subassembly, assembly, and system levels. Such a framework requires accurate, efficient and easy-to-use mathematical and computational models that are in sync with physical reality. The research work in this paper is designed to help an aerospace structural engineer move towards this goal by simulating dynamic impact to composite panels. First, the existing orthotropic visco-elastic visco-plastic material model in LS-DYNA commercial finite element program, MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE (MAT_213) is enhanced with the development and use of rate-dependent damage data. Using state-of-the-art experimental procedures, impact validation test data are created. Second, the versatility of the constitutive model is examined by its ability to simulate a low velocity (27 ft/s, 8 m/s) impact test, and two high velocity impact tests (385–417 ft/s, 117–127 m/s) that straddle the ballistic limit of the projectile and the composite panels. Third, these impact events are modeled using three different finite element types – under-integrated and fully-integrated solid elements, and fully-integrated thin shell elements. Insight into accuracy versus numerical efficiency is gained by comparing the performance of solid versus thin shell elements. The numerical results show that accurate predictions of these impact events can be obtained with reasonable effort and care.

Simulations↗

Jet Propulsion Laboratory: Annual Report 2000

Year 2000 began with an intense period of self-examination for the Jet Propulsion Laboratory. Late in the previous year, two Mars-bound missions failed as they were arriving at the red planet, disappointing engineers, scientists and the public at large. After a probing series of internal and external reviews, a redesigned Mars program emerged that is intended to be more robust and more tightly coupled to the questions that scientists are attempting to answer. NASA expressed a significant vote of confidence in JPL by assigning an ambitious project to the Laboratory - to design, build and fly twin rovers to Mars in 2003. Among other missions and research programs, the news was more gratifying. Another Mars orbiter completed its first year of mapping operations, gathering more pictures than those collected over the entire missions of the two Viking orbiters. Stalwart spacecraft such as Galileo continued to deliver scientific discoveries, while a new generation of smaller solar system exploration missions got under way. In Earth sciences, a growing array of spaceborne instruments and satellites gave us new perspectives on the home planet, including an imaging radar mission on the Space Shuttle and two JPL instruments that began science operations after their launch on NASA's Terra orbiter in late 1999. In astronomy and physics, a JPL-built camera continued to perform flawlessly on NASA's Hubble Space Telescope, offering previously unglimpsed views of the deep universe.

Jet Propulsion Laboratory (JPL)↗

Rheology improvement for silicon nitride and resin slurries for vat photopolymerization printing and sintering

This work presents the formulation, rheological characterization, and sintering of silicon nitride (Si₃N₄) slurries for vat photopolymerization (VPP) using digital light processing (DLP). Bimodal Si₃N₄ powder was dispersed into commercial photopolymer resin using two different dispersants with opposing effects on surface charge, resulting in varied slurry stability and flow behavior. Slurries were engineered to exhibit shear-thinning behavior suitable for VPP, and their flow properties were quantified using a power-law fluid model. The formulations achieved cure depths of approximately 40 µm and enabled printing of green bodies. Post-processing included thermal debinding and liquid-phase sintering, yielding primarily β-Si₃N₄ with a minor Y-Si-Al-O-N glass phase. The sintered parts reached ~85% of theoretical density and demonstrated a flexural strength of ~330 MPa. Microstructural analysis revealed closed porosity along with some defects related to powder agglomeration and interlayer adhesion. These findings provide insights into slurry formulation strategies for additive manufacturing of high-performance non-oxide ceramics.

Aerospace engineering↗

Jet Propulsion Laboratory: Annual Report 2002

The year 2002 brought advances on many fronts in our space exploration ventures. A new orbiter settled in at Mars and delivered tantalizing science results suggesting a vast store of water ice under the planet's surface, a discovery that may have profound consequences for exploring Mars. A long-lived spacecraft made its final fly-bys of Jupiter's moons, while another started its final approach toward Saturn and yet another flew by an asteroid on its way to a comet. A new ocean satellite began science observations, joined in Earth orbit by a pair of spacecraft measuring our home planets gravity field, as well as JPL instruments on NASA and Japanese satellites. A major new infrared observatory and a pair of Mars rovers were readied for launch. All told, JPL is now communicating with 14 spacecraft cast like gems across the velvet expanses of the solar system. It is a far cry from the early 1960's, when JPL engineers made prodigious efforts to get the first planetary explorers off the ground and into space - an achievement of which we were especially mindful this year, as 2002 marked the 40th anniversary of the first successful planetary mission, Mariner 2, which barely reached our closest planetary neighbor, Venus. Added to this anniversary were celebrations surrounding the 25th anniversaries of the launches of Voyagers 1 and 2, two remarkable spacecraft that are still flying and are actively probing the outer realms of the solar system. These events of the past and present provide an occasion for reflection on the remarkable era of exploration that we at the Jet Propulsion Laboratory are privileged to be a part of. As 2002 neared its end, the Laboratory had yet another reason for celebration, as a new five-year management contract between NASA and the California Institute of Technology was signed that calls for a closer working relationship with NASA and other NASA centers as a member of the 'One NASA' team. There is a strong emphasis on cost control and management, areas in which we can improve, enabling us to become more competitive. This new agreement again confirms NASA's trust and faith in Caltech and JPL, in which we should all take great pride. If the history of JPL were a book, we are on the verge of turning the page to one that promises to be one of the most exciting and busiest chapters in JPL's history. In 2003 and 2004, we will launch 11 spacecraft or major payloads. We will land two rovers on Mars; put a spacecraft in orbit around Saturn, deliver a probe to the surface of its largest moon, Titan, and map Titan's surface withimaging radar; send a spacecraft past a comet collecting samples from its tail, while another one is launched toward a comet impact; bring a capsule back to Earth with the first samples ever collected beyond the orbit of the Moon; map the skies in the ultraviolet as well as the infrared spectrum to unprecedented accuracy; and continue the mapping of ocean topography and winds on our home planet, Earth.

National Aeronautics and Space Administration (NAS↗

Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints

This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.

36 MATERIALS SCIENCE↗

Physicochemical properties of digital light processing 3D-Printed alumina and mullite ceramics

Alumina ceramics fabricated using conventional techniques such as uniaxial pressing or injection molding are popular due to their low density, excellent insulation, and mechanical properties. However, these methods often limit the fabrication of complex geometries with high dimensional accuracy due to tooling constraints and limited design freedom. To overcome these limitations, this study employed Digital Light Processing (DLP) additive manufacturing (AM), which enables the production of precise structures. In addition, the optimization of sintering parameters to enhance the densification and performance of alumina and mullite ceramics was investigated, with a specific focus on how varying sintering temperatures and hold times affect part shrinkage, geometric accuracy, and material integrity. Flexural strength of both alumina and mullite specimens was clearly influenced by the way the layers was stacked. When layers were arranged across the direction of the applied load (Z = 4; XZ), the strength was higher than when they were stacked along the same direction as the load (Z = 3; XY). Weibull analysis based on these results showed high modulus values across all samples, indicating good reliability in the flexural strength measurements. This reliability, combined with the clear influence of sintering parameters, highlights how processing conditions effect the material properties and mechanical performance of parts produced through DLP additive manufacturing. In conclusion, these findings open new avenues for ceramic AM across various applications, enhancing the potential for innovation in fields such as aerospace, biomedical engineering, and energy.

36 MATERIALS SCIENCE↗

SEEMS: A Single Event Effects and Muon Spectroscopy facility at the Spallation Neutron Source

This study outlines a concept that would leverage the existing proton accelerator at the Spallation Neutron Source (SNS) of Oak Ridge National Laboratory to enable transformative science via one world-class facility serving two missions: Single Event Effects (SEE) and Muon Spectroscopy (μSR). The μSR portion would deliver the world’s highest flux and highest resolution pulsed muon beams for material characterization purposes, with precision and capabilities well beyond comparable facilities. The SEE capabilities deliver neutron, proton, and muon beams for aerospace industries that are facing an impending challenge to certify equipment for safe and reliable behavior under bombardment from atmospheric radiation originating from cosmic and solar rays. With negligible impact on the primary neutron scattering mission of the SNS, the proposed facility will have enormous benefits for both science and industry. Herein, we have designated this facility “SEEMS.”

47 OTHER INSTRUMENTATION↗

The ATTO-Campina site: A new observatory for tropical convection and gas-aerosol-cloud-precipitation interactions in the Amazon

We present results from ATTO-Campina, a new permanent observational site in central Amazon, about 4 km from the ATTO towers. Operational since 2020, ATTO-Campina characterizes atmospheric, cloud and rainfall properties through remote sensing. The goal is to provide continuous, complementary measurements to the ATTO towers, addressing the rainforest’s complex gas-aerosol-cloud-precipitation dynamics. Using a 3.5-year dataset, we classified convective clouds into three types: shallow cumulus (ShCu), congestus (Con) or (Deep) clouds. The shallow-to-deep transition takes about three hours, starting with ShCu formation at 11:00 local time. The accumulated rainfall peak follows at about 16:00. Only weak downdrafts are present in the upper troposphere where previous studies indicate new particle formation (NPF) occurrence. Strong downdrafts are mostly limited to heights below 5 km. Con and Deep convective days have higher concentrations of ultrafine aerosol and lower concentrations of accumulation-mode particles compared to ShCu. Convective clouds also significantly modify gas mixing ratios. Deep convective clouds are associated with high near-surface O3, consistent with downward transport from the midtroposphere. Our results showcase the added detail achieved by integrating data from the ATTO towers and ATTO-Campina sites. Together, these sites support better understanding of interconnected gas-aerosol-cloud-precipitation processes in the Amazon and their evolution under climate change.

54 ENVIRONMENTAL SCIENCES↗

High-Efficiency, Low-Cost III-V Solar Cells by Dynamic Hydride Vapor Phase Epitaxy Coupled with Rapid, Polishing-Free Wafer Reuse through Orientation-Optimized (110) Spalling

We demonstrated (110) GaAs solar cells grown by D-HVPE with equivalent performance and material quality relative to (100) devices. Also, we developed a procedure for repeatable wafer-scale spalling of (110) GaAs. Spalled surfaces were free of the facets founds in (100) GaAs spalling, the large arrest lines found in (100) Ge spalling, and surface features greater than 3 µm in peak-to-valley height, which can otherwise degrade the efficiency of regrown III-V devices. A sub-µm step-terrace morphology was discovered on the post-spall wafer surface, resulting from the restricted cleavage system of GaAs, but we developed understanding of the factors that determine the resulting morphology, enabling ample opportunity for optimization of morphologies suitable for device growth and spall depth waste minimization on (110) GaAs. Lastly, we demonstrated a device grown on a previously spalled surface with only 8% relative efficiency difference to a cell grown on a new unspalled wafer. Significant optimization of the substrate regrowth conditions are required to enable higher efficiency, but these results highlight the promise of (110)-oriented devices coupled with substrate reuse by spalling as a pathway for low-cost III-V photovoltaics.

14 SOLAR ENERGY↗

Improved hardening theory for cyclic plasticity.

A temperature-dependent version of a combined hardening theory, including isotropic and kinematic hardening, is presented within the framework of recent plasticity formulations. This theory has been found to be especially useful in finite-element analysis of aerospace vehicle engines under conditions of large plastic strain and low-cycle fatigue.

Vos, R. G.↗