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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Materials Genome Initiative

The Materials Genome Initiative (MGI) project element is a cross-Center effort that is focused on the integration of computational tools to simulate manufacturing processes and materials behavior. These computational simulations will be utilized to gain understanding of processes and materials behavior to accelerate process development and certification to more efficiently integrate new materials in existing NASA projects and to lead to the design of new materials for improved performance. This NASA effort looks to collaborate with efforts at other government agencies and universities working under the national MGI. MGI plans to develop integrated computational/experimental/ processing methodologies for accelerating discovery and insertion of materials to satisfy NASA's unique mission demands. The challenges include validated design tools that incorporate materials properties, processes, and design requirements; and materials process control to rapidly mature emerging manufacturing methods and develop certified manufacturing processes

Vickers, John↗
NASA NTRS1993

Novel cost controlled materials and processing for primary structures

Textile laminates, developed a number of years ago, have recently been shown to be applicable to primary aircraft structures for both small and large components. Such structures have the potential to reduce acquisition costs but require advanced automated processing to keep costs controlled while verifying product reliability and assuring structural integrity, durability and affordable life-cycle costs. Recently, resin systems and graphite-reinforced woven shapes have been developed that have the potential for improved RTM processes for aircraft structures. Ciba-Geigy, Brochier Division has registered an RTM prepreg reinforcement called 'Injectex' that has shown effectivity for aircraft components. Other novel approaches discussed are thermotropic resins producing components by injection molding and ceramic polymers for long-duration hot structures. The potential of such materials and processing will be reviewed along with initial information/data available to date.

Dastin, S. J.↗
NASA NTRS1986

Distributed automatic control of technological processes in conditions of weightlessness

Some problems associated with the automatic control of liquid metal and plasma systems under conditions of weightlessness are examined, with particular reference to the problem of stability of liquid equilibrium configurations. The theoretical fundamentals of automatic control of processes in electrically conducting continuous media are outlined, and means of using electromagnetic fields for simulating technological processes in a space environment are discussed.

Kukhtenko, A. I.↗
NASA NTRS2006

Evolution and Control of 2219 Aluminum Microstructural Features through Electron Beam Freeform Fabrication

Electron beam freeform fabrication (EBF3) is a new layer-additive process that has been developed for near-net shape fabrication of complex structures. EBF3 uses an electron beam to create a molten pool on the surface of a substrate. Wire is fed into the molten pool and the part translated with respect to the beam to build up a 3-dimensional structure one layer at a time. Unlike many other freeform fabrication processes, the energy coupling of the electron beam is extremely well suited to processing of aluminum alloys. The layer-additive nature of the EBF3 process results in a tortuous thermal path producing complex microstructures including: small homogeneous equiaxed grains; dendritic growth contained within larger grains; and/or pervasive dendritic formation in the interpass regions of the deposits. Several process control variables contribute to the formation of these different microstructures, including translation speed, wire feed rate, beam current and accelerating voltage. In electron beam processing, higher accelerating voltages embed the energy deeper below the surface of the substrate. Two EBF3 systems have been established at NASA Langley, one with a low-voltage (10-30kV) and the other a high-voltage (30-60 kV) electron beam gun. Aluminum alloy 2219 was processed over a range of different variables to explore the design space and correlate the resultant microstructures with the processing parameters. This report is specifically exploring the impact of accelerating voltage. Of particular interest is correlating energy to the resultant material characteristics to determine the potential of achieving microstructural control through precise management of the heat flux and cooling rates during deposition.

Taminger, Karen M.↗
DOE OSTI2025

Correlating processing variables to material properties in recycled polypropylene: A data‐driven approach

Abstract Polypropylene (PP) is one of the most widely used plastics, yet its recycling remains limited, with less than 1% of solid waste PP being reprocessed. Mechanical recycling through extrusion is the most practical method, but inconsistent reprocessing conditions introduce variability in material properties. While temperature, screw speed, and residence time influence the thermomechanical stress applied during reprocessing, there are no standardized guidelines for optimizing these parameters. This study examines how these factors shape the properties of recycled PP, using conditions designed to mimic post‐industrial recycled (PIR) scrap. Residence time was measured using colorimetric tracking and correlated with molecular weight, viscosity, and mechanical properties over multiple extrusion cycles. Data‐driven modeling, including response surface methodology, support vector machines, and artificial neural networks, identified processing temperature as the dominant factor in material degradation, followed by residence time. Mechanical properties remained stable, while viscosity decreased predictably with increasing residence time. By linking reprocessing conditions to property evolution, this study provides a method to optimize processing parameters and reduce variability in recycled PP. These findings help manufacturers improve process control, making recycled PP more predictable for reuse in manufacturing. Highlights Study of PIR‐quality PP without additives or compatibilizers. Residence time analysis shows processing temperature drives PP property changes. Mark‐Houwink enables quick molecular weight checks for quality control. Models predict mechanical and rheological shifts in reprocessing. Optimized processing parameters minimize property degradation in recycling.

Estela‐García, John E. [Polymer Engineering Center↗
DOE OSTI2024

Effects of input gradient regularization on neural networks time-series forecasting of thermal power systems

This study proposes using neural networks, specifically gated recurrent unit (GRU), long-short-term memory (LSTM), and transformer networks, to improve control strategies in a 450 MW coal-fired power plant. However, neural networks face issues of becoming overly dependent on just a few variables to make predictions, which negatively impacts control decisions that rely on the model to determine the value of all manipulated variables. The paper introduces regularization techniques, including noise injection and input gradient regularization, during the training phase. Here, the work presents novel contributions in adapting neural networks to control industrial systems and applying regularization techniques from computer vision to industrial process control. Results demonstrate the effectiveness of input gradient regularization in reducing model dependence on subsets of variables, emphasizing the balance between fidelity and controllability. Further exploration is recommended, including the development of recurrent transformers, closed-loop control testing, and a sensitivity analysis on computer models to provide further insight.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Leveraging Multiple Raman Excitation Wavelength Systems for Process Monitoring of Nuclear Waste Streams

Processing nuclear waste from sites such as Hanford is a significant environmental cleanup need while being a significant logistical challenge. Integration of process monitoring tools, that can provide in situ and real-time feedback about the process, can significantly alleviate needs to collect grab samples for process control and product characterization. Raman spectroscopy paired with chemometric analysis is one process monitoring tool that can provide chemical composition information on a large number of chemical targets in nuclear waste streams. However, methods to improve limits of detection as well as drop uncertainty in quantification are needed. Optimizing instrument specifications can achieve this, here this is demonstrated by comparing limits of detection for key analytes when using Raman systems with 671 nm, 532 nm, and 405 nm excitation wavelengths. Generally, limits of detection decease (allowing the measurement of lower salt concentrations) with decreasing wavelength. Similarly, data collection times and averaging were optimized. Finally, multiple chemometric modeling approaches were leveraged, including multiblock methods that combined data from all three Raman systems to simultaneously quantify targets with improved sensitivity.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1993

A modular, programmable measurement system for physiological and spaceflight applications

The NASA-Ames Sensors 2000! Program has developed a small, compact, modular, programmable, sensor signal conditioning and measurement system, initially targeted for Life Sciences Spaceflight Programs. The system consists of a twelve-slot, multi-layer, distributed function backplane, a digital microcontroller/memory subsystem, conditioned and isolated power supplies, and six application-specific, physiological signal conditioners. Each signal condition is capable of being programmed for gains, offsets, calibration and operate modes, and, in some cases, selectable outputs and functional modes. Presently, the system has the capability for measuring ECG, EMG, EEG, Temperature, Respiration, Pressure, Force, and Acceleration parameters, in physiological ranges. The measurement system makes heavy use of surface-mount packaging technology, resulting in plug in modules sized 125x55 mm. The complete 12-slot system is contained within a volume of 220x150x70mm. The system's capabilities extend well beyond the specific objectives of NASA programs. Indeed, the potential commercial uses of the technology are virtually limitless. In addition to applications in medical and biomedical sensing, the system might also be used in process control situations, in clinical or research environments, in general instrumentation systems, factory processing, or any other applications where high quality measurements are required.

Hines, John W.↗
NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗
NASA NTRS2008

Floating Pressure Conversion and Equipment Upgrades of Two 3.5kw, 20k, Helium Refrigerators

Two helium refrigerators, each rated for 3.5KW at 20K, are used at NASA s Johnson Space Center (JSC) in Building No. 32 to provide cryo-pumping within two large thermal-vacuum chambers. These refrigerators were originally commissioned in 1996. Equipment refurbishment and upgrades to the controls of these refrigerators were recently completed. This paper describes some of the mechanical and control issues that necessitated the equipment refurbishment and controls change-over. It will describe the modifications and the new process control which allows the refrigerators to take advantage of the Ganni Cycle "floating pressure" control technology. The upgrades -- the controls philosophy change-over to the floating pressure control technology and the newly refurbished equipment -- have greatly improved the performance, stability, and efficiency of these two refrigerators. The upgrades have also given the operators more information and details about the operational status of the main components (compressors, expanders etc.) of the refrigerators at all operating conditions (i.e.: at various loads in the vacuum chambers). Capabilities, configuration, and performance data pre, and post, upgrading will be presented.

Homan, Jonathan↗
DOE OSTI2017

What Lies Beneath Can Be Imaged

The Hanford Site was quickly established to help end World War II, making history for producing the plutonium used in the world’s first nuclear weapons. Throughout the Cold War years, Hanford employees produced plutonium for most of the more than 60,000 weapons in the U.S. nuclear arsenal stockpile. Today, the once highly active nuclear reactors are shut down. And the mission at Hanford turned full-circle as scientists, engineers and specialists work to clean up our nation’s most contaminated nuclear site. PNNL Computational Geophysicist Tim Johnson is helping decision-makers understand the complexity and breadth of the contamination in soils at Hanford. Tim and others are applying remote, high-resolution geophysical imaging to determine the extent of contamination in the soil below the surface and understand the processes controlling its movement. They also provide real-time imaging of remediation processes that are working to limit the movement of contaminants below the surface and toward water resources. Geophysical imaging simply means that PNNL scientists are combining the techniques of geology, physics, mathematics and chemistry with supercomputer modeling to create three-dimensional images of the waste and its movement. These real-time, remote images are essential in reducing the uncertainty associated with cleanup costs and remediation technologies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2011

Microlith-based Structured Sorbent for Carbon Dioxide, Humidity, and Trace Contaminant Control in Manned Space Habitats

To support continued manned space exploration, the development of atmosphere revitalization systems that are lightweight, compact, durable, and power efficient is a key challenge. The systems should be adaptable for use in a variety of habitats and should offer operational functionality to either expel removed constituents or capture them for closedloop recovery. As mission durations increase and exploration goals reach beyond low earth orbit, the need for regenerable adsorption processes for continuous removal of CO2 and trace contaminants from cabin air becomes critical. Precision Combustion, Inc. (PCI) and NASA Marshall (MSFC) have been developing an Engineered Structured Sorbents (ESS) approach based on PCI s patented Microlith technology to meet the requirements of future, extended human spaceflight explorations. This technology offers the inherent performance and safety attributes of zeolite and other sorbents with greater structural integrity, regenerability, and process control, thereby providing potential durability and efficiency improvements over current state-of-the-art systems. The major advantages of the ESS explored in this study are realized through the use of metal substrates to provide structural integrity (i.e., less partition of sorbents) and enhanced thermal control during the sorption process. The Microlith technology also offers a unique internal resistive heating capability that shows potential for short regeneration time and reduced power requirement compared to conventional systems. This paper presents the design, development, and performance results of the integrated adsorber modules for removing CO2, water vapor, and trace chemical contaminants. A related effort that utilizes the adsorber modules for sorption of toxic industrial chemicals is also discussed. Finally, the development of a 4-person two-leg ESS system for continuous CO2 removal is also presented.

Junaedi, Christian↗
NASA NTRS1997

Precision Casting via Advanced Simulation and Manufacturing

A two-year program was conducted to develop and commercially implement selected casting manufacturing technologies to enable significant reductions in the costs of castings, increase the complexity and dimensional accuracy of castings, and reduce the development times for delivery of high quality castings. The industry-led R&D project was cost shared with NASA's Aerospace Industry Technology Program (AITP). The Rocketdyne Division of Boeing North American, Inc. served as the team lead with participation from Lockheed Martin, Ford Motor Company, Howmet Corporation, PCC Airfoils, General Electric, UES, Inc., University of Alabama, Auburn University, Robinson, Inc., Aracor, and NASA-LeRC. The technical effort was organized into four distinct tasks. The accomplishments reported herein. Task 1.0 developed advanced simulation technology for core molding. Ford headed up this task. On this program, a specialized core machine was designed and built. Task 2.0 focused on intelligent process control for precision core molding. Howmet led this effort. The primary focus of these experimental efforts was to characterize the process parameters that have a strong impact on dimensional control issues of injection molded cores during their fabrication. Task 3.0 developed and applied rapid prototyping to produce near net shape castings. Rocketdyne was responsible for this task. CAD files were generated using reverse engineering, rapid prototype patterns were fabricated using SLS and SLA, and castings produced and evaluated. Task 4.0 was aimed at developing technology transfer. Rocketdyne coordinated this task. Casting related technology, explored and evaluated in the first three tasks of this program, was implemented into manufacturing processes.

Source record↗
NASA NTRS2006

Evolution and Control of 2219 Aluminum Microstructural Features Through Electron Beam Freeform Fabrication

The layer-additive nature of the electron beam freeform fabrication (EBF3) process results in a tortuous thermal path producing complex microstructures including: small homogeneous equiaxed grains; dendritic growth contained within larger grains; and/or pervasive dendritic formation in the interpass regions of the deposits. Several process control variables contribute to the formation of these different microstructures, including translation speed, wire feed rate, beam current and accelerating voltage. In electron beam processing, higher accelerating voltages embed the energy deeper below the surface of the substrate. Two EBF3 systems have been established at NASA Langley, one with a low-voltage (10-30kV) and the other a high-voltage (30-60 kV) electron beam gun. Aluminum alloy 2219 was processed over a range of different variables to explore the design space and correlate the resultant microstructures with the processing parameters. This report is specifically exploring the impact of accelerating voltage. Of particular interest is correlating energy to the resultant material characteristics to determine the potential of achieving microstructural control through precise management of the heat flux and cooling rates during deposition.

Taminger, Karen M.↗
NASA NTRS1990

Temperature and melt solid interface control during crystal growth

Findings on the adaptive control of a transparent Bridgman crystal growth furnace are summarized. The task of the process controller is to establish a user specified axial temperature profile by controlling the temperatures in eight heating zones. The furnace controller is built around a computer. Adaptive PID (Proportional Integral Derivative) and Pole Placement control algorithms are applied. The need for adaptive controller stems from the fact that the zone dynamics changes with respect to time. The controller was tested extensively on the Lead Bromide crystal growth. Several different temperature profiles and ampoule's translational rates are tried. The feasibility of solid liquid interface quantification by image processing was determined. The interface is observed by a color video camera and the image data file is processed to determine if the interface is flat, convex or concave.

Batur, Celal↗
DOE OSTI2023

Train, Inform, Borrow, or Combine? Approaches to Process–Guided Deep Learning for Groundwater–Influenced Stream Temperature Prediction

Although groundwater discharge is a critical stream temperature control process, it is not explicitly represented in many stream temperature models, an omission that may reduce predictive accuracy, hinder management of aquatic habitat, and decrease user confidence. We assessed the performance of a previously-described process-guided deep learning model of stream temperature in the Delaware River Basin (USA). We found lower accuracy (root mean square error [RMSE] of 1.71 versus 1.35°C) and stronger seasonal bias (absolute mean monthly bias of 1.06 vs. 0.68°C) for reaches primarily influenced by deep groundwater as compared to atmospheric conditions. We then tested four approaches for improving groundwater process representation: (a) a custom loss function leveraging the unique patterns of air and water temperature coupling characteristic of different temperature drivers, (b) inclusion of additional groundwater-relevant catchment attributes, (c) incorporation of additional process model outputs, and (d) a composite model. The custom loss function and the additional attributes significantly improved the predictive accuracy in groundwater-dominated reaches (RMSE of 1.37 and 1.26°C) and reduced the seasonal bias (absolute mean monthly bias of 0.44 and 0.48°C), but neither approach could identify holdout groundwater reaches. Variable importance analysis indicates the custom loss function nudges the model to use the existing inputs more efficiently, whereas with the added features the model relies on a broader suite of inputs. This analysis is a substantial step toward more accurately representing groundwater discharge processes in stream temperature models and will improve predictive accuracy and inform habitat management.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1988

Controlling basins of attraction in a neural network-based telemetry monitor

The size of the basins of attraction around fixed points in recurrent neural nets (NNs) can be modified by a training process. Controlling these attractive regions by presenting training data with various amount of noise added to the prototype signal vectors is discussed. Application of this technique to signal processing results in a classification system whose sensitivity can be controlled. This new technique is applied to the classification of temporal sequences in telemetry data.

Bell, Benjamin↗