Search NASA⌕ Search

SEARCH · Search NASA

Results for “Advanced Manufacturing Technologies”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

NASA's Exploration and In-Space Services (NExIS) Division OSAM-1 Propellant Transfer Subsystem Progress 2020

National Aeronautics and Space Administration (NASA)’s Exploration and In-Space Services (NExIS) Division of Goddard Space Flight Center has been developing technology for the On-orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1) to robotically refuel heritage and new satellites on-orbit. OSAM-1, formerly known as Restore-L, successfully passed an important NASA milestone called Key Decision Point-C (KDP-C), receiving agency-level approval for its implementation. The decision point also establishes the mission’s official schedule and budget. The OSAM-1 spacecraft, Servicing Payload and the Space Infrastructure Dexterous Robot (SPIDER) payload will refuel a satellite in space, assemble a communications antenna and manufacture a beam. By demonstrating these capabilities, the mission is advancing never-before tested technologies for use in future missions (by NASA and other government organizations and private industry). The mission is funded by the Technology Demonstration Missions program within NASA’s Space Technology Mission Directorate. This paper covers a review of servicing extensibility and critical technologies that are being developed within NExIS with a focus on the fluid transfer refueling technology within the framework of the Propellant Transfer Subsystem (PTS). An overview of the planned initial technology demonstration servicing mission via the OSAM-1 Space Vehicle is provided as an extension of the technology development progress reported in 20181, and 20192. The general objectives, challenges, and key technologies are presented as an introduction to the context of the OSAM-1 mission, and a precursor to the OSAM-1 PTS specific development status. Development and progress of the Hose Management Assembly (HMA) and Propellant Transfer Assembly (PTA) are discussed. HMA risk reduction test results including those of thermal vacuum testing are presented. Important analytical results are discussed and progress of drawings and procedures developed for the fabrication and testing phase are shown. A summary of the PTS overall verification status and design activities prepared for the critical design peer review are presented. Procurement progress is shown with status on long, medium, and short term efforts to acquire the hardware required to support the mission objectives. Technology development, challenges, and testing status are discussed with particular regard to the OSAM-1 specific key assemblies including the PTA and HMA along with the overall integrated flight mockup of the spacecraft to client fluid transfer testing conducted in the servicing testbeds. The paper concludes with key milestones leading to the goal of on-orbit refueling to be demonstrated in 2024. The overall mission Launch Readiness Date (LRD) has been realigned to accommodate budget profiles and incorporation of additional on-orbit assembly and manufacturing demonstration efforts.

Propellant transfer, satellite servicing↗
DOE OSTI2021

Artificial Intelligence for Multiphysics Nuclear Design Optimization with Additive Manufacturing

The geometric flexibility of additively manufactured metals and ceramics generates a very large and open design space that requires advanced modeling and simulation tools for physics simulations and the rigorous definition of design problems. This effort deploys artificial intelligence (AI) and machine learning (ML) algorithms to understand the design space, evaluate potential designs, and more efficiently generate optimized results. The Transformational Challenge Reactor (TCR) program is leveraging advances in several scientific areas—including materials, manufacturing, sensors and control systems, data analytics, and high-fidelity modeling and simulation—to accelerate the design, manufacturing, qualification, and deployment of advanced nuclear energy systems. Through a manufacturing-informed design approach, the TCR program seeks to integrate digital data for rapid nuclear innovation; accelerate the adoption of advances in manufacturing, materials, and computational sciences for nuclear applications; and dramatically reduce deployment costs and timelines for new nuclear reactor technologies. This report documents efforts under the TCR program to leverage advanced modeling and simulation techniques driven by AI/ML algorithms on high-performance computing (HPC) systems to yield more optimized TCR core designs. A multiphysics ML surrogate model was developed to run on the HPC architectures. The surrogate model is trained on high-fidelity simulation data of coupled neutronics and thermofluidics and is used to quickly evaluate thousands of candidate core designs in parallel, which drives the evolution of the cooling channel shapes to minimize temperature peaking and material stress. Outcomes from these activities provide design information and feedback into the core design efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2018

Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

NASA's strategic plan calls for the development of enabling technologies, improved production methods, and advanced design and analysis tools related to the agency's objectives to expand human presence in the solar system. NASA seeks to advance exploration, science, innovation, benefits to humanity, and international collaboration, as well as facilitate and utilize U.S. commercial capabilities to deliver cargo and crew to space.

factsheet↗
DOE OSTI2025

Advances in high-pressure and high-temperature heat exchangers: Innovations via additive manufacturing and their applications

This paper provides a comprehensive overview of technological developments and applications for high-pressure and high-temperature (HPHT) heat exchangers produced through additive manufacturing (AM) techniques. As the demand for high-efficiency energy systems has been rising, the role of heat exchangers for thermal management and transport is becoming increasingly crucial. In this context, AM has emerged as a promising manufacturing solution to address the challenges posed by higher operating temperatures and/or pressures. This paper delves into three primary areas: the exploration of HPHT regimes supported by conventional heat exchangers, the impact of AM processes on thermal transport devices, and the discussion focused on HPHT heat exchangers produced via AM. The study examines the traditional manufacturing processes, materials, structures and geometries, and limitations of the commonly used heat exchangers for HPHT applications. Furthermore, it highlights the potential of AM in optimizing HPHT heat exchanger design, by reviewing studies that enable uniform flow distribution, minimization of fouling, and thermo-hydraulic performance augmentation without compromising structural stability. While addressing the limitations of cost, size, and other constraints, this study offers insights into the possibilities of AM in revolutionizing HPHT heat exchanger technology. The goal has been to fill the gap in literature by summarizing key studies, findings, and limitations, presenting a detailed examination, and proposing new areas for research. In conclusion, this review contributes to a deeper understanding of AM’s role in advancing HPHT heat exchangers for future energy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Energy efficiency in industrial drying: A hybrid ultrasonic system with a novel dynamic optimization framework

Drying processes are among the most energy-consuming operations in industrial and manufacturing settings, demanding strategic selection, design, and control for enhanced efficiency. Advancing drying technologies is critical for improving sustainability, lowering energy use, reducing carbon emissions, and minimizing waste. This study explores two innovative strategies aimed at transforming drying processes into sustainable, low-carbon systems by reducing energy consumption, minimizing waste, and maintaining a strong emphasis on preserving product quality. The first strategy showcases a sub-pilot scale hybrid ultrasonic-convective dryer for agrifood products. This technology, powered by electricity (process electrification), integrates non-thermal ultrasonic dehydration with convective heating and is presented as a sustainable and energy-efficient solution that enhances eco-friendly practices. The second strategy involves introducing and implementing a novel, multiobjective, mixed integer dynamic optimization technique to determine the optimal time-dependent process parameter values for the drying operation. This optimization technique yields operating conditions that are piecewise constant in time aiming to maximize the energy efficiency of the hybrid ultrasonic-convective dryer while ensuring strict adherence to product quality constraints. By adopting the hybrid ultrasonic-convective dryer, a notable 35% improvement in energy efficiency was achieved compared to conventional hot-air drying systems for drying apple slices. The proposed optimization framework further enhanced energy efficiency by nearly 14% over the most efficient process on the identical testbed, under static operating conditions. The reported enhancements have been experimentally validated. Regarding drying time (thereby improving production yield), the developed hybrid ultrasonic-convective dryer demonstrates as much as a 41% reduction in total processing time, which is further optimized by an additional 10% using our proposed optimization framework. The research outcomes have profound implications for the design and operation of drying systems, encompassing crucial aspects such as process electrification, cost-effectiveness, energy savings, time efficiency, product yield, product quality, and process automation.

Dynamic optimization↗
DOE OSTI2023

Multi-technique characterization of spray coated and roll-to-roll coated gas diffusion fuel cell electrodes

Here this work reports the characterization of catalyst layer (CL) structure and composition for a set of gas-diffusion electrodes (GDEs) fabricated by different coating methods with the goal of developing a better understanding of CL processing-structure-property-performance relationships. The CL coating techniques used in this study were ultrasonic spray coating, and two roll-to-roll (R2R) methods - gravure and slot die. Scanning transmission electron microscopy (STEM) coupled with X-ray energy dispersive spectroscopy (EDS) analysis of GDE cross-sections provided bulk information, while scanning electron microscopy (SEM) with EDS and X-ray photoelectron spectroscopy (XPS) were used to investigate the near surface and surface composition of the CLs that will be in direct contact with the membrane once the membrane electrode assembly (MEA) is constructed. This study demonstrates that common quantification parameters, namely the F:Pt ratio extracted from cross-sectional STEM-EDS maps and top-down CL measurements with SEM and XPS, along with roughness parameters quantified from SEM micrographs are useful parameters in explaining and potentially predicting performance trends. Additionally, it highlights the importance of understanding key CL surface properties for advancing the manufacturability of high-performance components for polymer electrolyte membrane (PEM) technologies.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Indistinguishable photons from an artificial atom in silicon photonics

Silicon is the ideal material for building electronic and photonic circuits at scale. Integrated photonic quantum technologies in silicon offer a promising path to scaling by leveraging advanced semiconductor manufacturing and integration capabilities. However, the lack of deterministic quantum light sources and strong photon-photon interactions in silicon poses a challenge to scalability. In this work, we demonstrate an indistinguishable photon source in silicon photonics based on an artificial atom. We show that a G center in a silicon waveguide can generate high-purity telecom-band single photons. We perform high-resolution spectroscopy and time-delayed two-photon interference to demonstrate the indistinguishability of single photons emitted from a G center in a silicon waveguide. Our results show that artificial atoms in silicon photonics can source single photons suitable for photonic quantum networks and processors.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Challenge-driven printing strategies toward high-performance solid-state lithium batteries

Solid-state lithium batteries (SSLBs) are promising candidates for replacing traditional liquid-based Li-ion batteries and revolutionizing battery systems for electric vehicles and portable devices. However, longstanding issues such as form factors, interfacial contact resistance, balance between ion conductivity and mechanical strength, and manufacturing processability limit their applications. In this review we present how advanced printing technologies can help to mitigate typical problems in main components of SSLBs and improve device performance. Here we first introduce the common printing techniques for energy storage devices, then focus on the issues and corresponding printing strategies for anodes, cathodes, and solid-state electrolytes to guide the construction of energy-dense, free-form SSLBs. The features and effects of the printed structures are emphasized, as well. We conclude by discussing the problems associated with printing technologies and the potential research directions for printed solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2023

Ameliorating Global Challenges: Globalization, Geopolitics, Basic & Applied Research, and Research Security

We are confronted with a myriad of global challenges, from extreme weather events, occurring at higher frequencies than at any point in history, to pollution, food insecurity, clean water shortages, and fundamentally limited natural resources and materials. The largest number of people inhabit our planet today and enjoy the highest standard of living - though not equally distributed across the world - compared to any prior moment in history. To sustain this quality of life, we are largely reliant on fossil fuel sources, which are responsible for more greenhouse gas emissions by weight each day than the collective weight of all humans that inhabit the planet. Ameliorating these global challenges will require elements of solutions that include advances in basic and applied research, innovative global engineering, materials discovery, new technologies, manufacturing at scale, resilient and adaptable infrastructure, carbon-free energy sources and storage technologies, and new supply chain networks and markets. Success will require constructive collaborative efforts between researchers in countries located in every continent of this planet. For any of these goals to be realized in a timely fashion, geopolitical leaders must become better educated about this existential challenge and incentivized to act.

applied research↗
DOE OSTI2021

The Elevated-Temperature Cyclic Properties of Alloy 316H Fabricated by Powder Metallurgy Hot Isostatic Pressing (Rev.1)

Powder metallurgy hot isostatic pressing (PM HIP), an advanced manufacturing technique, is viewed by the Department of Energy as a “transformational technology” for heavy section manufacturing of nuclear components. Although PM HIP is a mature technology, it has not been qualified in Section III, Division 5 for elevated-temperature nuclear construction. This work seeks to demonstrate a PM HIP qualification method for elevated-temperature nuclear construction that is based on allowable material characteristics. Specifically, the elevated-temperature cyclic properties of PM HIP 316H are investigated. The creep-fatigue properties of PM HIP 316H are significantly degraded compared to those of wrought. Current PM HIP practices are not able to fabricate elevated-temperature nuclear components with creep-fatigue properties that are equivalent to or better than traditional wrought components. A research and development program is proposed for qualifying PM HIP 316H for elevated-temperature nuclear construction.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Technoeconomic Assessment of Phosphoric Acid and Rare Earth Element Recovery from Phosphoric Acid Sludge

Sustainability faces many challenges, including the availability of materials necessary for technological advancement. Rare earth elements (REEs), for example, are key materials for several manufacturing industries that can unlock renewable energy and sustainable development. In this study, a decanter centrifuge has been employed to successfully separated phosphoric acid and REE-containing particles from phosphoric acid sludge with concentrations ranging from 1000 to 2200 ppm REEs. Operating efficiently with up to 35 wt.% solids, the centrifuge was demonstrated to achieve approximately 95% phosphoric acid recovery and 90% REE recovery in a single pass, eliminating the need for additional processing steps. This breakthrough supports a proposed rare earth oxide (REO) recovery process integrating phosphoric acid (PA), elemental phosphorus (P4), and REO into two potential pathways: PA-REO and PA-P4-REO. These processes aim to reintroduce recovered phosphoric acid into the main product to significantly increase output and revenue. Post-separation, phosphorus-rich particles can be converted to P4, while REE-containing solids undergo further treatment including acid leaching, extraction/stripping, precipitation, and calcination to produce a marketable REO material. Technoeconomic analysis indicates promising profitability, with the PA-REO process showing a delta net present value (ΔNPV) of USD 441.8 million over a 12-year period and expected return within a year of construction, while the PA-P4-REO process yields a ΔNPV of USD 178.7 million over a 12-year return period. Both pathways offer robust financial prospects and demonstrate the feasibility of commercial-scale REO recovery from phosphoric acid sludge, offering an economically feasible approach to produce REEs for future sustainable development challenges related to sustainability.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Composite structural materials

A decade long program to develop critical advanced composite technology in the areas of physical properties, structural concept and analysis, manufacturing, reliability, and life predictions is reviewed. Specific goals are discussed. The status of the chemical vapor deposition effects on carbon fiber properties; inelastic deformation of metal matrix laminates; fatigue damage in fibrous MMC laminates; delamination fracture toughness in thermoplastic matrix composites; and numerical analysis of composite micromechanical behavior are presented.

Loewy, Robert G.↗
NASA NTRS1990

Advanced composites research and development for transport aircraft

This paper highlights past experiences, lessons learned, state-of-the-art and current research activities directed at providing an integrated 'affordable' data base for composite structures. Composite secondary and empennage structures are in production on several transport aircraft. The weight reduction potential of composite structures is well documented. However, the cost to develop and produce composite structures remains the major barrier to increased application of this technology to transport aircraft. Specific technology items that are being developed under the NASA Advanced Composites Technology Program are described. Materials, design concepts, structural mechanics methodology and manufacturing processes and equipment are under development or are emerging that are expected to lead to an integrated 'affordable' data base. Technology verification for the next decade is expected to require fabrication and testing of full-scale wing-box and fuselage-section components before certificatiaon can occur and production commitments can be made.

Davis, John G., Jr.↗
NASA NTRS1998

High-Temperature Compressor Material Development

The next generation of subsonic commercial aircraft will require engines with improved efficiency and greater durability at lower costs. To help achieve these goals, manufacturing technologies for the disks, airfoils, and impellers in the compressors of these advanced turbine engines are being developed by a team representing all four U.S. aircraft engine companies--GE Aircraft Engines, Pratt & Whitney, AlliedSignal Inc., and Allison Engine Company. This work is being funded by NASA's Advanced Subsonic Technology (AST) project.

Gayda, John↗
NASA NTRS2009

NASA SBIR Subtopic S2.04 "Advanced Optical Components"

The primary purpose of this subtopic is to develop and demonstrate technologies to manufacture ultra-low-cost precision optical systems for very large x-ray, UV/optical or infrared telescopes. Potential solutions include but are not limited to direct precision machining, rapid optical fabrication, slumping or replication technologies to manufacture 1 to 2 meter (or larger) precision quality mirror or lens segments (either normal incidence for uv/optical/infrared or grazing incidence for x-ray). An additional key enabling technology for UV/optical telescopes is a broadband (from 100 nm to 2500 nm) high-reflectivity mirror coating with extremely uniform amplitude and polarization properties which can be deposited on 1 to 3 meter class mirror.

Stahl, H. Philip↗
NASA NTRSDate not supplied

Design of a Thermal Testbed for Metrology of Active Antennas

NASA mission requirements have driven an increased interest in active phased array antennas (APAA) for space-based user communication terminals. Recent advancements in 5G technology have driven down the cost of APAA development and manufacturing all while providing a technology solution that covers many existing Ka-Band satellite communication spectrum bands. While these developments have provided ample opportunities to leverage new chips and arrays for use in space, there is also a need to evaluate these antennas in a relevant environment. Active arrays, as designed for use in 5G, require thermal management to avoid damage to the device as well as to maintain performance. Measured performance under various thermal conditions is essential both for understanding overall APAA performance and ensuring operation is within required tolerances. To address these measurement needs, the SmallSat Ka-band Operations User Terminal (SKOUT) project at the NASA Glenn Research Center (GRC) developed a test environment that combines traditional antenna and communication system metrology with a conduction cooling/heating thermal control system to simulate the space thermal environment. This paper will address the metrologysystem design and performance specifications as well as test article setup and operation. Tests that are typically performed at ambient temperature can now be performed over the typical temperature range of a Low Earth Orbit (LEO) mission. These tests include error vector magnitude (EVM), gain to noise temperature (G/T), antenna patterns, and non-linear characterization. The paper will cover the configuration for each test and provide results from a recent test campaign. Results illustrate the importance of higher fidelity environmental testing when evaluating the performance of an APAA.

active phased array↗
DOE OSTI2022

Contech to Accelerate Cleantech: Seeding Emerging Innovation Programs for Construction Productivity and Energy Efficiency Integration; Preprint

Investments in U.S.-based start-ups that focus on advanced building construction technologies to increase construction productivity (contech) surged to approximately $3.1 billion in 2018 (as per Crunchbase data). More recently, emerging programs by government funding agencies, philanthropic foundations, and venture capitalists have been instrumental in supporting contech start-ups for innovations that increase productivity of energy efficiency integration and accelerate clean energy technologies (cleantech) for the buildings sector. These programs include R&D support and funding mechanisms for contech and cleantech. Traditionally, contech and cleantech are considered as two different innovation ecosystems. To enhance and scale up energy efficiency in buildings, creative programs that bring together contech and cleantech are critical. This paper provides a landscape assessment of the "contech-for-cleantech" innovation ecosystem in the U.S. and its impact in accelerating technology readiness and the development pipeline of "contech-for-cleantech". Technologies highlighted are robotics for retrofits, prefabrication of energy-efficient products, and advanced manufacturing of low-carbon net-zero buildings construction. Programs discussed include those led by (1) government funding agencies: American-Made Challenges with prizes like E-ROBOT for retrofits with robotics, (2) philanthropic foundations: Wells Fargo Innovation Incubator (IN2) that includes focus on energy efficiency and prefabrication, and (3) venture capitalists: Shadow Ventures Green Building Accelerator program which provides funding support to start-ups with ambitious plans for decarbonizing the built environment. This paper will also expand upon robust processes and criteria involved in judging and down-selection of start-ups through vetting and feedback from national lab researchers and industry experts in both cleantech and contech.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes

Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗