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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 469 records · Page 26

Sapphire Substrate Trenching to Advance Superconducting High-Coherence Quantum Devices

Achieving longer coherence times in superconducting qubits is essential for advancing quantum information processing and enabling scalable quantum computing. This work presents an innovative fabrication strategy focused on sapphire trenching of the substrate of superconducting high-coherence quantum devices, developed by the SQMS Nanofabrication Taskforce in collaboration with the materials characterization team. In this talk, we present a method to efficiently and consistently trench into the sapphire substrate, without compromising the surface roughness or profile of the etched sapphire. In the literature, trenching in the substrate has been shown to decrease losses, unwanted coupling and thermal stress. Sapphire’s strong covalent bonds make it harder to etch compared to silicon, yet it is more favorable for high-coherence quantum devices due to its lower dielectric losses. This innovative technique opens new possibilities for superconducting qubit fabrication: we fabricated high coherence qubit chips on sapphire substrates with trenching, to demonstrate that it will help pushing towards higher coherence times. By integrating this work with ongoing junction process optimization, design innovation, materials characterization and exploration, we outline a clear pathway toward transmon coherence times reaching millisecond scales and beyond.

Garattoni, S. [Fermilab]↗

Manufacturing Full-Scale High Gradient Copper Accelerators: Electron Beam Welding and Allied Processes

This DOE ARDAP-funded study examines the technical and business feasibility of manufacturing high-gradient normal conducting RF (NCRF) copper accelerating structures using electron beam welding (EBW) instead of conventional high-temperature brazing. The core motivation is material performance: brazing softens copper significantly, while hard copper alloys have demonstrated ~75% higher operational gradients in SLAC tests, making cold-joining techniques highly attractive. EBW, applied to split-cell (half or quadrant) structure designs, preserves copper hardness away from the weld joint and simplifies machining — but industrial process optimization remains immature and a substantial learning curve is expected. The business case was modeled for two scenarios: a greenfield EBW linac company (> $10M upfront costs, viable above ~30 units/year) and an EBW division added to an existing accelerator firm to reduce risk and upfront costs, at the expense of being less optimal structure for the higher volume production. The study concludes that without a significant increase in demand, private investment alone cannot sustain this capability, and recommends federal support through R&D grants, procurement incentives, and CAPEX cost-sharing to incubate domestic EBW-NCRF manufacturing — with the existing-company model.

43 PARTICLE ACCELERATORS↗

A User-Friendly GUI Tool for Automated Microstructural Analysis of Fiber-Reinforced Composites and Porous Structures

Understanding and quantifying microstructural features such as fiber orientation and porosity is critical for predicting the mechanical behavior and performance of fiber-reinforced polymer composites. Traditional manual analysis is time-consuming, subjective, and unsuitable for high-throughput datasets. We present a graphical user interface (GUI) application that automates the analysis of microscopy images to extract key microstructural metrics, including fiber orientation tensors, fiber orientation distribution, porosity and pore size distribution. The app integrates multiple image segmentation techniques including global and local thresholding, clustering, and region-based approaches, offering flexibility for different types of image qualities and features. Users can load microstructural images, select regions of interest and segmentation techniques tailored to their image dataset. It also addresses a critical challenge in fiber orientation analysis: the ambiguities caused by touching, overlapping, or partially cut fibers. It supports autorun examples for standardized workflows, enabling reproducible analysis and facilitating training and benchmarking. This tool significantly reduces manual intervention, enhances consistency, and accelerates data generation for structure–property modeling, process optimization, and digital materials research. The tool is intended for use by materials scientists, engineers, and researchers engaged in composite characterization, quality control, and machine learning-based microstructural studies.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗

Fabrication and Evaluation of Large Alumina Crucibles by Vat Photopolymerization Additive Manufacturing for High-Temperature Actinide Chemistry

Additive manufacturing (AM) offers opportunities to advance the design and function of ceramic tooling in high temperature actinide pyrochemistry. In technical ceramics such as alumina, conventional forming techniques often restrict design flexibility and can limit experimental progress. In this study, we investigate the use of vat photopolymerization (VP) with commercial resins to fabricate large-scale alumina crucibles, reaching dimensions up to 125 mm, which is significantly larger than typically reported for dense VP ceramics. Notably, these additively manufactured components are produced using consumer-grade hardware, which limits process control, but offers significant upside in scalability and accessibility. Using microscopy and X-ray computed tomography, the VP alumina parts have high bulk densities above 95%, but also the prevalence of AM-induced artifacts and surface defects. Mechanical testing showed these defects to significantly reduce flexural strength and compromise part reliability. Electrorefining trials under sustained exposure to molten salts and metals reveal mixed results, with the AM material exhibiting high chemical compatibility, but mechanical failures due to the reduced strength were prevalent. Our findings illustrate both the promise and current limitations of AM ceramics for actinide chemistry, and point toward future improvements in process optimization, design strategies, and part screening to enhance performance and reliability.

Materials science↗

Bio-Based Polyurethane Materials: Technical, Environmental, and Economic Insights

Polyurethane (PU) is widely used due to its attractive properties, but the shift to a low-carbon economy necessitates alternative, renewable feedstocks for its production. This review examines the synthesis, properties, and sustainability of bio-based PU materials, focusing on renewable resources such as lignin, vegetable oils, and polysaccharides. It discusses recent advances in bio-based polyols, their incorporation into PU formulations, and the use of bio-fillers like chitin and nanocellulose to improve mechanical, thermal, and biocompatibility properties. Despite promising material performance, challenges related to large-scale production, economic feasibility, and recycling technologies are highlighted. The paper also reviews life cycle assessment (LCA) studies, revealing the complex and context-dependent environmental benefits of bio-based PU materials. These studies indicate that while bio-based PU materials generally reduce greenhouse gas emissions and non-renewable energy use, their environmental performance varies depending on feedstock and formulation. The paper identifies key areas for future research, including improving biorefinery processes, optimizing crosslinker performance, and advancing recycling methods to unlock the full environmental and economic potential of bio-based PU in commercial applications.

Jayalath, Piumi↗

Correlating Superconducting Qubit Performance Losses to Sidewall Near-Field Scattering via Terahertz Nanophotonics

Elucidating dielectric losses, structural heterogeneity, and interface imperfections is critical for improving coherence in superconducting qubits. However, most diagnostics rely on destructive electron microscopy or low-throughput millikelvin quantum measurements. Here, we demonstrate noninvasive terahertz (THz) nano-imaging/-spectroscopy of encapsulated niobium transmon qubits, revealing sidewall near-field scattering that correlates with qubit coherence. We further employ a THz hyperspectral line scan to probe dielectric responses and field participation at Al junction interfaces. These findings highlight the promise of THz near-field methods as a high-throughput proxy characterization tool for guiding material selection and optimizing processing protocols to improve qubit and quantum circuit performance.

Kim, Richard H.J. [Ames Lab]↗

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗

Application of Monte Carlo techniques to optimization of high-energy beam transport in a stochastic environment

An algorithm employing a modified sequential random perturbation, or creeping random search, was applied to the problem of optimizing the parameters of a high-energy beam transport system. The stochastic solution of the mathematical model for first-order magnetic-field expansion allows the inclusion of state-variable constraints, and the inclusion of parameter constraints allowed by the method of algorithm application eliminates the possibility of infeasible solutions. The mathematical model and the algorithm were programmed for a real-time simulation facility; thus, two important features are provided to the beam designer: (1) a strong degree of man-machine communication (even to the extent of bypassing the algorithm and applying analog-matching techniques), and (2) extensive graphics for displaying information concerning both algorithm operation and transport-system behavior. Chromatic aberration was also included in the mathematical model and in the optimization process. Results presented show this method as yielding better solutions (in terms of resolutions) to the particular problem than those of a standard analog program as well as demonstrating flexibility, in terms of elements, constraints, and chromatic aberration, allowed by user interaction with both the algorithm and the stochastic model. Example of slit usage and a limited comparison of predicted results and actual results obtained with a 600 MeV cyclotron are given.

Parrish, R. V.↗

Resin/graphite fiber composites

High temperature resin matrices suitable for use in advanced graphite fiber composites for jet engine applications were evaluated. A series of planned, sequential screening experiments with resin systems in composite form were performed to reduce the number of candidates to a single A-type polyimide resin that repetitively produced void-free, high strength and modulus composites acceptable for use in the 550 F range for 1000 hours. An optimized processing procedure was established for this system. Extensive mechanical property studies characterized this single system, at room temperature, 500 F, 550 F and 600 F, for various exposure times.

Cavano, P. J.↗

Wing optimization for space shuttle orbiter vehicles

The results were presented of a parametric study performed to determine the optimum wing geometry for a proposed space shuttle orbiter. The results of the study establish the minimum weight wing for a series of wing-fuselage combinations subject to constraints on aerodynamic heating, wing trailing edge sweep, and wing over-hang. The study consists of a generalized design evaluation which has the flexibility of arbitrarily varying those wing parameters which influence the vehicle system design and its performance. The study is structured to allow inputs of aerodynamic, weight, aerothermal, structural and material data in a general form so that the influence of these parameters on the design optimization process can be isolated and identified. This procedure displays the sensitivity of the system design of variations in wing geometry. The parameters of interest are varied in a prescribed fashion on a selected fuselage and the effect on the total vehicle weight is determined. The primary variables investigated are: wing loading, aspect ratio, leading edge sweep, thickness ratio, and taper ratio.

Surber, T. E.↗

A symmetrical laser Doppler velocity meter and its application to turbulence characterization

A symmetrical method of optical heterodyning of the Doppler shifted scattered laser radiation developed for velocity measurements with a minimal instrumental spectral broadening and a high signal-to-noise ratio. The method employs two laser beams incident on the moving scatterer and does not use any reference beam for heterodyning. The Doppler signal frequency is independent of the scattering angle and the signal possesses no receiving aperture broadening. Optical alignment is simple. Typical values of the instrumental spectral broadening were approximately 0.8 percent of the center frequency of the Doppler signal, and the signal-to-noise ratio was approximately 25 dB, obtained from an air flow system using submicron dioctylphthalate scattering aerosol. Experimental and theoretical studies were made on the characteristics of the Doppler signal and the effect of system parameters in turbulent flow measurement. The optimization process involved in the beam optics and in the use of a spatial filter is described. For localized flow measurement in any direction of the three-dimensional orthogonal coordinates, the system, using uncorrected optical components, had a sensing volume which can be described by a sensitive length of 600 microns and a diameter of 100 microns.

Mazumder, M. K.↗

The selection of imaging systems for planetary photography from space vehicles.

Discussion of the selection of a type of imaging system for a specific mission which will maximize the return of scientific data while keeping development risk and cost to acceptable limits. A representative example is given which shows that the parameters of the optimizing process range from the scientific objectives through the engineering and programming constraints of the spacecraft and mission, to the characteristics of the types of systems. The selections for all planetary missions flown to date have been imaging systems using image tube cameras. Film cameras and mechanical scan cameras, however, have unique advantages which should find application in planetary exploration.

Smokler, M. I.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade-offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗

Noncoherent detection of periodic signals

The optimal Bayes detector for a general periodic waveform having uniform delay and additive white Gaussian noise is examined. It is shown that the detector is much more complex than that for the well known cases of pure sine waves (i.e. classical noncoherent detection) and narrowband signals. An interpretation of the optimal processing is presented, and several implementations are discussed. The results have application to the noncoherent detection of optical square waves.

Gagliardi, R. M.↗

Preliminary performance estimates of an oblique, all-wing, remotely piloted vehicle for air-to-air combat

A computerized aircraft synthesis program has been used to assess the effects of various vehicle and mission parameters on the performance of an oblique, all-wing, remotely piloted vehicle (RPV) for the highly maneuverable, air-to-air combat role. The study mission consists of an outbound cruise, an acceleration phase, a series of subsonic and supersonic turns, and a return cruise. The results are presented in terms of both the required vehicle weight to accomplish this mission and the combat effectiveness as measured by turning and acceleration capability. This report describes the synthesis program, the mission, the vehicle, and results from sensitivity studies. An optimization process has been used to establish the nominal RPV configuration of the oblique, all-wing concept for the specified mission. In comparison to a previously studied conventional wing-body canard design for the same mission, this oblique, all-wing nominal vehicle is lighter in weight and has higher performance.

Nelms, W. P., Jr.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade-offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗