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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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565 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Effect of directed energy deposition process parameter on build quality of tantalum

Tantalum is a refractory metal used in a variety of harsh environment applications. Additive manufacturing of tantalum is limited based on its high melting point and affinity for oxygen. Directed Energy Deposition is an additive manufacturing technique with rapid deposition time and compositional flexibility within builds. Additively manufactured tantalum is susceptible to a variety of material and process-based defects. Various lack-of-fusion defects were identified resulting from excessive powder feed rates or insufficient laser power. Oxygen impurities in some samples caused cracking and increased material hardness. Precipitates were identified in the highly oxidized samples which were printed immediately after the build chamber was opened. High-density, low-defect parts were successfully produced. The effects of scan speed, laser power, and powder feed rate on density and defects were analyzed. A processing window was identified for producing high-quality parts which requires adequately high laser power and lower powder feed rate.

DED↗
NASA NTRS2026

Influence of Processing Parameters on the Mechanical Properties of 3D Printed Borosilicate Particulate Reinforced Polymer Composites

Emerging composite materials are expanding the potential of additive manufacturing and enabling applications previously restricted by traditional manufacturing methods. The multi-phase nature of these composite materials combined with the complex in-ternal geometry of additively manufactured parts have enabled unique behavior, and potentially new applications. Additionally, these materials can be pyrolyzed to create dense metal, ceramic, and glass parts with geometries typically not achievable by tra-ditional processes. Additive manufacturing of borosilicate glass-based systems can open new applications in nuclear engineering, astronomy, and bone regrowth therapy. To elucidate the process-parameter relationship of borosilicate-polylactic acid (PLA) composites, mechanical testing was conducted and compared with a pure polylactic acid polymer baseline. Test specimens were fabricated by fused-filament fabrication with minimal post-processing. Yield strength, ultimate strength, and elastic modulus were calculated from stress-strain curves. Optical and scanning electron microscopy were conducted to observe the specimen microstructure before and after testing. The highest compressive yield strength for the composite was 28.22 MPa, and the highest compressive yield strength for PLA was 49.30 MPa. Print orientation was found to benefit the composite material but have a detrimental effect on the pure matrix material. An elastic modulus of 2.66 GPa was recorded for the borosilicate-PLA composite at 100% infill, 1 shell wall, and layer lines parallel to compression axis. Microscopy revealed that lower modulus composite specimens had the particulates re-distributed within the matrix. Tensile testing was done according to a polymer testing standard, which caused difficulties obtaining consistent fracture within the gauge length.

mechanical testing↗
DOE OSTI2024

Remote-Contact Catalysis for Target-Diameter Semiconducting Carbon Nanotube Arrays

Electrostatic catalysis has been an exciting development in chemical synthesis (beyond enzymes catalysis1 ) in recent years, boosting reaction rates and selectively producing certain reaction products2 . Most of the studies to date have been focused on using external electric field (EEF) to rearrange the charge distribution in small molecule reactions such as Diels-Alder addition3 , carbene reaction4 , etc. However, in order for these EEFs to be effective, a field on the order of 1 V/nm (10 MV/cm) is required, and the direction of the EEF has to be aligned with the reaction axis5 . Such a large and oriented EEF will be challenging for large-scale implementation, or materials growth with multiple reaction axis or steps. Here, we demonstrate that the energy band at the tip of an individual single-walled carbon nanotube6 (SWCNT) can be spontaneously shifted in a high-permittivity growth environment, with its other end in contact with a low-work function electrode (e.g., hafnium carbide or titanium carbide7 ). By adjusting the Fermi level at a point where there is a substantial disparity in the density of states (DOS) between semiconducting (s-) and metallic (m-) SWCNTs8 , we achieve effective electrostatic catalysis for s-SWCNT growth assisted by a weak EEF perturbation (200V/cm). This approach enables the production of high-purity (99.92%) s-SWCNT horizontal arrays with narrow diameter distribution (0.95±0.04 nm), targeting the requirement of advanced SWCNT-based electronics for future computing9-11. These findings highlight the potential of electrostatic catalysis in precise materials growth, especially for s-SWCNTs, and pave the way for the development of advanced SWCNT-based electronics12.

Wang, Jiangtao [Department of Electrical Engineeri↗
DOE OSTI2026

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗
NASA NTRS1995

A review of nickel hydrogen battery technology

This paper on nickel hydrogen batteries is an overview of the various nickel hydrogen battery design options, technical accomplishments, validation test results and trends. There is more than one nickel hydrogen battery design, each having its advantage for specific applications. The major battery designs are individual pressure vessel (IPV), common pressure vessel (CPV), bipolar and low pressure metal hydride. State-of-the-art (SOA) nickel hydrogen batteries are replacing nickel cadmium batteries in almost all geosynchronous orbit (GEO) applications requiring power above 1 kW. However, for the more severe low earth orbit (LEO) applications (greater than 30,000 cycles), the current cycle life of 4000 to 10,000 cycles at 60 percent DOD should be improved. A NASA Lewis Research Center innovative advanced design IPV nickel hydrogen cell led to a breakthrough in cycle life enabling LEO applications at deep depths of discharge (DOD). A trend for some future satellites is to increase the power level to greater than 6 kW. Another trend is to decrease the power to less than 1 kW for small low cost satellites. Hence, the challenge is to reduce battery mass, volume and cost. A key is to develop a light weight nickel electrode and alternate battery designs. A common pressure vessel (CPV) nickel hydrogen battery is emerging as a viable alternative to the IPV design. It has the advantage of reduced mass, volume and manufacturing costs. A 10 Ah CPV battery has successfully provided power on the relatively short lived Clementine Spacecraft. A bipolar nickel hydrogen battery design has been demonstrated (15,000 LEO cycles, 40 percent DOD). The advantage is also a significant reduction in volume, a modest reduction in mass, and like most bipolar designs, features a high pulse power capability. A low pressure aerospace nickel metal hydride battery cell has been developed and is on the market. It is a prismatic design which has the advantage of a significant reduction in volume and a reduction in manufacturing cost.

Smithrick, John J.↗
NASA NTRSDate not supplied

Off‑World Additive Manufacturing - Augmenting NASA‑STD‑6030

This slide presents a summary for a soon to be released white paper on augmenting NASA-STD-6030 for off-world manufacturing. It examines the driving need for in-space manufacturing and its corresponding risks, challenges, potential solutions, and technology development needed to qualify a process.

NASA-STD-6030↗
NASA NTRSDate not supplied

Design and Analysis of Battery Thermal Management Systems

Thermal management of battery cell packs is a critically needed technology. The purpose of this work is to design new and improved Battery Thermal Management Systems (BTMS) for use in electric airplanes. The BTMS should be 3D printable and hold twelve to sixteen 18650 batteries. To minimize aircraft’s weight, an actively air-cooled battery pack was chosen to avoid the excess weight of water-cooled and phase change material (PCM) cooled packs. As a result, significant changes were made to remove all metal in the pack and replace it with lower density polymer matrix composites (PMCs) which can be additively manufactured. Two air cooled battery pack configurations (traditional propeller fans & bladeless fans) were designed, modeled, and compared. These packs were first modeled in SolidWorks 2021 3D CAD, then imported into COMSOL MultiPhysics to be studied using the “Heat Transfer in Solids and Fluids” module. The design with the bladeless fans eliminated the need to use high conductivity heavy metal to remove unwanted thermal energy. These bladeless fans were designed entirely out of PMCs. This thermal pack design weighs 0.04 kg less than that of the traditional propeller fans design and has increased the battery pack energy density by 8.25 Wh/kg.

Thermal Management System for Battery Packs↗
NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗
DOE OSTI2026

Domestically Manufactured Fuel Cells for Heavy Duty Applications

This project, funded by the U.S. Department of Energy under Award DE-EE0009248, advances the domestic development of fuel-cell stack technologies for heavy-duty transportation applications. The work directly supports the Million-Mile Fuel Cell Truck (M2FCT) initiative by improving performance, durability, and manufacturability—key requirements for next-generation hydrogen fuel-cell systems.

08 HYDROGEN↗