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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 487 records · Page 27

Diagenesis is key to unlocking outcrop fracture data suitable for quantitative extrapolation to geothermal targets

Exceptionally large, well-exposed sandstone outcrops in New York provide insights into folds, deformation bands, and fractures that could influence permeability, heat exchange, and stimulation outcomes of geothermal reservoir targets. Cambrian Potsdam Sandstone with <5% porosity contains decimeter-scale open, angular-limbed monoclines <0.5 km apart with associated low-porosity mm-wide cataclastic deformation bands. Crossing and abutting relationships among sub-vertical opening-mode fractures show four chronological Sets A–D, striking NNW, NE, NW, and ENE, respectively. Fracture lengths and heights range from millimeters to tens of meters. Sets A and C macro-fractures, and possibly B and D, contain quartz deposits. All sets have abundant associated quartz cemented microfractures that also record set orientations and crosscutting relations. Quartz cement deposits—evidence of diagenesis—are the key to identifying attributes of outcrop fractures suitable for extrapolation to geothermal targets in sandstones because they show which fractures formed in the subsurface. Set A fluid inclusion homogenization temperatures (120°C–129°C) are compatible with fracture at >3 km depth. Fractures are stiff and those ≥0.05 mm (Set C) and ≥0.1 mm (Set A) are open and potentially conducive to flow. Sets A and D are abundant in outcrops with close fracture spacing—0.18 m and 0.68 m, respectively—and define a rectangular connectivity network dominated by crossing and abutting X and Y nodes. Set A aperture distributions follow a power law with slope –0.8 up to 0.15 mm; other sets have lognormal distributions. Set A and D microfractures are weakly clustered, while macro-fractures commonly have 1D anticlustered (regular or periodic) arrangements at shorter length scales (<0.2 m). Sub-horizontal fractures are barren and may have formed near the surface. Fracture heights, lengths, and spatial arrangements show good trace connectivity but low open connectivity. For geothermal applications, outcrop results predict low initial well-test permeabilities owing to quartz disconnecting open fractures, but stimulation of closely spaced microfractures and partly open macro-fractures could yield high surface area for heat exchange. Quantitative extrapolation of key fracture attributes like abundance, orientation, spatial arrangement, length, and open fracture connectivity is possible from outcrops to fractured reservoirs if differing thermal histories and diagenesis are accounted for.

02 PETROLEUM↗

Processability and Material Behavior of NiTi Shape Memory Alloys Using Wire Laser-Directed Energy Deposition (WL-DED)

Utilizing additive manufacturing (AM) techniques with shape memory alloys (SMAs) like NiTi shows great promise for fabricating highly flexible and functionally superior 3D metallic structures. Compared to methods relying on powder feedstocks, wire-based additive manufacturing processes provide a viable alternative, addressing challenges such as chemical composition instability, material availability, higher feedstock costs, and limitations on part size while simplifying process development. This study presented a novel approach by thoroughly assessing the printability of Ni-rich Ni55.94Ti (Wt. %) SMA using the wire laser-directed energy deposition (WL-DED) technique, addressing the existing knowledge gap regarding the laser wire-feed metal additive manufacturing of NiTi alloys. For the first time, the impact of processing parameters—specifically laser power (400–1000 W) and transverse speed (300–900 mm/min)—on single-track fabrication using NiTi wires in the WL-DED process was examined. An optimal range of process parameters was determined to achieve high-quality prints with minimal defects, such as wire dripping, stubbing, and overfilling. Building upon these findings, we printed five distinct cubes, demonstrating the feasibility of producing nearly porosity-free specimens. Notably, this study investigated the effect of energy density on the printed part density, impurity pick-up, transformation temperature, and hardness of the manufactured NiTi cubes. The results from the cube study demonstrated that varying energy densities (46.66–70 J/mm3) significantly affected the quality of the deposits. Lower to intermediate energy densities achieved high relative densities (>99%) and favorable phase transformation temperatures. In contrast, higher energy densities led to instability in melt pool shape, increased porosity, and discrepancies in phase transformation temperatures. These findings highlighted the critical role of precise parameter control in achieving functional NiTi parts and offer valuable insights for advancing AM techniques in fabricating larger high-quality NiTi components. Additionally, our research highlighted important considerations for civil engineering applications, particularly in the development of seismic dampers for energy dissipation in structures, offering a promising solution for enhancing structural performance and energy management in critical infrastructure.

Dabbaghi, Hediyeh↗

Glancing Angle Deposition in Gas Sensing: Bridging Morphological Innovations and Sensor Performances

Glancing Angle Deposition (GLAD) has emerged as a versatile and powerful nanofabrication technique for developing next-generation gas sensors by enabling precise control over nanostructure geometry, porosity, and material composition. Through dynamic substrate tilting and rotation, GLAD facilitates the fabrication of highly porous, anisotropic nanostructures, such as aligned, tilted, zigzag, helical, and multilayered nanorods, with tunable surface area and diffusion pathways optimized for gas detection. This review provides a comprehensive synthesis of recent advances in GLAD-based gas sensor design, focusing on how structural engineering and material integration converge to enhance sensor performance. Key materials strategies include the construction of heterojunctions and core–shell architectures, controlled doping, and nanoparticle decoration using noble metals or metal oxides to amplify charge transfer, catalytic activity, and redox responsiveness. GLAD-fabricated nanostructures have been effectively deployed across multiple gas sensing modalities, including resistive, capacitive, piezoelectric, and optical platforms, where their high aspect ratios, tailored porosity, and defect-rich surfaces facilitate enhanced gas adsorption kinetics and efficient signal transduction. These devices exhibit high sensitivity and selectivity toward a range of analytes, including NO2, CO, H2S, and volatile organic compounds (VOCs), with detection limits often reaching the parts-per-billion level. Emerging innovations, such as photo-assisted sensing and integration with artificial intelligence for data analysis and pattern recognition, further extend the capabilities of GLAD-based systems for multifunctional, real-time, and adaptive sensing. Finally, current challenges and future research directions are discussed, emphasizing the promise of GLAD as a scalable platform for next-generation gas sensing technologies.

Chemistry↗

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 ↗

Welding of commercial base plates is investigated

Investigation of aluminum alloy welds reveals that the combinations of metallic elements with hydrogen are not capable of producing weld porosity themselves, rather they tend to increase the amount of porosity only in the presence of arc contamination by water vapor.

Cheever, D. L.↗

Diffusion in thoriated and nonthoriated nickel and nickel-chromium alloys at 1260 C

Various solid-solid diffusion couples were assembled from thoriated and nonthoriated nickel-base alloys, welded, and diffusion annealed at 1260 C. Concentration profiles indicated that a thoria dispersion does not affect diffusion in Cr(alloy):Ni and Ni-4.8Al:Ni types of couples unless a fine grain structure is retained by the thoria particles. Metallography revealed the presence of thoria-free bands in the thoriated-Ni side of the diffusion zone. The bands contained grain boundaries and, in some cases, non-Kirkendall porosity. A mechanism based on the operation of vacancy sources is proposed to explain the thoria-free bands. In addition, a particular DS-NiCr:Ni couple had negligible Kirkendall porosity. This behavior was related to the grain structure of the particular lot of DS-NiCr.

Whittenberger, J. D.↗

Integration of NASA-sponsored studies on aluminum welding

The results are presented of numerous studies relating to aluminum alloy welding. The subjects covered include: (1) effects of porosity on weld joint performance, (2) sources of porosity, (3) weld thermal effects, (4) residual stresses and distortion, and (5) manufacturing process system control.

Masubuchi, K.↗

Drag characteristics of a disk-gap-band parachute with a nominal diameter of 1.65 meters at Mach numbers from 2.0 to 3.0

Supersonic wind-tunnel tests were conducted with disk-gap-band parachute models having a nominal diameter of 1.65 meters and geometric porosities of 10.0, 12.5, and 15.0 percent. Canopy inflation characteristics, angles of attack, and drag performance are presented for deployment behind forebody base extensions which were free to oscillate in pitch and yaw. The effect of increasing suspension-line length on canopy motions and drag performance is included, and the drag performance of a model with 12.5 percent geometric porosity is compared with results from flight tests of a parachute with a nominal diameter of 12.19 meters.

Mayhue, R. J.↗

An Exploratory Study of the Microstructure of Mullite Fibers

The microstructures of mullite composition fibers were examined by transmission electron microscopic techniques and by X-ray diffraction analyses. Both spun and monofilament fiber structures contained little porosity, nor did the degree of porosity change after heating the monofilament to 1205 C for one half hour. Thermal exposure produced crystallite growth and nucleation from the amorphous phase in all three of the spun fibers. After 116 hours at 1426 C, the crystallites of the standard spun fibers became contiguous. In addition, the surface crystallites of these fibers were found to be more than twice as large as the interior crystallites.

Santoro, G.↗

Wind tunnel blockage and support interference effects on winged-body models at Mach numbers from 0.6 to 1.0

Three sting-mounted winged-body models with tunnel blockages of 0.1, 1.0, and 2.0 percent were tested in the Lewis Research Center's 8- by 6- Foot Supersonic Wind Tunnel. Fuselage pressures were obtained over a Mach number range of 0.6 to 1.0 at angles of attack from 0 deg to 4 deg. Two other types of model support were investigated, which included simulated wing-tip and fuselage support-strut mountings. The effects of tunnel porosity and sidewall geometry were also investigated. Model blockage effects were small up to M sub 0 = 0.95. At higher speeds the major blockage effect observed was a displacement of the local transonic terminal shocks on the model. The effects of the wing-tip type of model support were small up to M sub 0 = 0.95, but disturbances were observed on the fuselage at higher speeds. Changes in local tunnel porosity were effective in reducing the disturbances up to M sub 0 = 0.975, but a change in sidewall geometry was not.

Blaha, B. J.↗

Development of sputtered techniques for thrust chambers, task 1

Filler materials proposed for use in the sputter fabrication regeneratively cooled thrust chambers were evaluated. Low melting castable alloys, CERROBEND. CERROCAST, and CERROTRU, slurry applied SERMETEL 481 and flame-sprayed aluminum were investigated as filler materials. Sputter deposition from a cylindrical cathode inverted magnestron was used to apply an OFHC copper closeout layer to filled OFHC copper ribbed-wall cylindrical substrates. The sputtered closeout layer structure was evaluated with respect to filler material contamination, predeposition machining and finishing operations, and deposition parameters. The application of aluminum by flame-spraying resulted in excessiver filler porosity. Though the outgassing from this porosity was found to be detrimental to the closeout layer structure, bond strengths in excess of 10,500 psi were achieved. Removal of the aluminum from the grooves was readily accomplished by leaching in a 7.0 molar solution of sodium hydroxide at 353 K. Of the other filler materials evaluated, CERROTRU was found to be the most suitable material with respect to completely filling the ribbed-wall cylinders and vacuum system compatibility. However, bond contamination resulted in low closeout layer bond strength with the CERROTRU filler. CERROBEND, CERROCAST, and SERMETEL 481 were found to be unacceptable as filler materials.

Mullaly, J. R.↗

Drag and stability characteristics of a variety of reefed and unreefed parachute configurations at Mach 1.80 with an empirical correlation for supersonic Mach numbers

An investigation was conducted at Mach 1.80 in the Langley 4-foot supersonic pressure tunnel to determine the effects of variation in reefing ratio and geometric porosity on the drag and stability characteristics of four basic canopy types deployed in the wake of a cone-cylinder forebody. The basic designs included cross, hemisflo, disk-gap-band, and extended-skirt canopies; however, modular cross and standard flat canopies and a ballute were also investigated. An empirical correlation was determined which provides a fair estimation of the drag coefficients in transonic and supersonic flow for parachutes of specified geometric porosity and reefing ratio.

Couch, L. M.↗

Capillary flow through heat-pipe wicks

Theoretical expressions are obtained for the capillary-pressure limit and permeability of a fibrous wick in terms of the porosity and fiber diameter. Hysteresis in capillary pressure is included through the introduction of an empirical hysteresis constant. A partial-saturation model based on the statistical distribution of local porosity requires an additional empirical constant, the standard deviation. The theory is compared to results of a beta-ray absorption experiment that measured the liquid content of a partially saturated wick and to results of permeability measurements on partially and fully saturated wicks. A simple wick-weighing experiment is described that yields values for the empirical hysteresis constant and the standard deviation. Theoretical results are used to design an optimum wick.

Eninger, J. E.↗

Wind-Tunnel Investigation of the Effect of Porous Spoilers on the Wake of a Subsonic Transport Model

Tests were conducted in the Ames Research Center 40- by 80-Foot Wind Tunnel to determine how porosity of wing spoilers on a B-747 airplane would affect the rolling moments imposed on an aircraft following in the wake. It was found that spoilers with 40 percent porosity and hole diameter to thickness ratio of 1.1 were just as effective in reducing the rolling moment imposed on the follower as solid spoilers, for the case of two spoilers per wing panel (6.4 percent semispan each) with a following model whose span was 20 percent of the span of the generator. When a larger following model was tested, whose span was 50 percent of that of the generator, the effectiveness of the two spoilers per wing was substantially reduced.

Corsiglia, V. R.↗

Inlet total pressure loss due to acoustic wall treatment

The effect of diffuser wall acoustic treatment on inlet total pressure loss was experimentally determined. Data were obtained by testing an inlet model with 10 different acoustically treated diffusers differing only in the design of the Helmholtz resonator acoustic treatment. Tests were conducted in a wind tunnel at forward velocities to 41 meters per second for inlet throat Mach numbers of .5 to .8 and angles of attack as high as 50 degrees. Results indicate a pressure loss penalty due to acoustic treatment that increases linearly with the porosity of the acoustic facing sheet. For a surface porosity of 14 percent the total pressure loss was 21 percent greater than that for an untreated inlet.

Miller, B. A.↗

Development of technology for the fabrication of reliable laminar flow control panels on subsonic transports

The feasibility of using porous composite materials (Kevlar, Doweave, and Leno Weave) as lightweight, efficient laminar flow control (LFC) surface materials is compared to the metallic 319L stainless Dynapore surfaces and electron beam drilled composite surfaces. Areas investigated include: (1) selection of the LFC-suitable surface materials, structural materials, and fabrication techniques for the LFC aircraft skins; (2) aerodynamic static air flow test results in terms of pressure drop through the LFC panel and the corresponding effective porosity; (3) structural design definition and analyses of the panels, and (4) contamination effects on static drop and effective porosity. Conclusions are presented and discussed.

Source record↗

Inlet total pressure loss due to acoustic wall treatment

Experimental determination of the effect of diffuser wall acoustic treatment on inlet total pressure loss. Data were obtained by testing an inlet model with 10 different acoustically treated diffusers differing only in the design of the Helmholtz resonator acoustic treatment. Tests were conducted in a wind tunnel at forward velocities to 41 meters per second for inlet throat Mach numbers of .5 to .8 and angles of attack as high as 50 degrees. Results indicate a pressure loss penalty due to acoustic treatment that increases linearly with the porosity of the acoustic facing sheet. For a surface porosity of 14% the total pressure loss was 21% greater than that for an untreated inlet. The penalty resulting from treatment increased for average throat Mach numbers above approximately .7 where local regions of sonic or supersonic surface flow were encountered. Pressure loss over the treatment was not affected by the presence of noise.

Miller, B. A.↗

Friction factor for isothermal and nonisothermal flow through porous media

Measurements were performed to determine the pressure drops for gaseous flow through porous materials of different microstructures, porosities, and thickness under isothermal and nonisothermal conditions at various temperature levels. Results were satisfactorily correlated by a simple equation relating the friction factor to the Reynolds number and porosities.

Koh, J. C.↗