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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

Detection of CFRP Composite Manufacturing Defects Using a Guided Wave Approach

NASA Langley Research Center is investigating a guided-wave based defect detection technique for as-fabricated carbon fiber reinforced polymer (CFRP) composites. This technique will be extended to perform in-process cure monitoring, defect detection and size determination, and ultimately a closed-loop process control to maximize composite part quality and consistency. The overall objective of this work is to determine the capability and limitations of the proposed defect detection technique, as well as the number and types of sensors needed to identify the size, type, and location of the predominant types of manufacturing defects associated with laminate layup and cure. This includes, porosity, gaps, overlaps, through-the-thickness fiber waviness, and in-plane fiber waviness. The present study focuses on detection of the porosity formed from variations in the matrix curing process, and on local overlaps intentionally introduced during layup of the prepreg. By terminating the cycle prematurely, three 24-ply unidirectional composite panels were manufactured such that each subsequent panel had a higher final degree of cure, and lower level of porosity. It was demonstrated that the group velocity, normal to the fiber direction, of a guided wave mode increased by 5.52 percent from the first panel to the second panel and 1.26 percent from the second panel to the third panel. Therefore, group velocity was utilized as a metric for degree of cure and porosity measurements. A fully non-contact guided wave hybrid system composed of an air-coupled transducer and a laser Doppler vibrometer (LDV) was used for the detection and size determination of an overlap By transforming the plate response from the time-space domain to the frequency-wavenumber domain, the total wavefield was then separated into the incident and backscatter waves. The overlap region was accurately imaged by using a zero-lag cross-correlation (ZLCC) imaging condition, implying the incident and backscattered waves are in phase over the overlap boundaries.

Hudson, Tyler B.↗
NASA NTRS1991

Single board system for fuzzy inference

The very large scale integration (VLSI) implementation of a fuzzy logic inference mechanism allows the use of rule-based control and decision making in demanding real-time applications. Researchers designed a full custom VLSI inference engine. The chip was fabricated using CMOS technology. The chip consists of 688,000 transistors of which 476,000 are used for RAM memory. The fuzzy logic inference engine board system incorporates the custom designed integrated circuit into a standard VMEbus environment. The Fuzzy Logic system uses Transistor-Transistor Logic (TTL) parts to provide the interface between the Fuzzy chip and a standard, double height VMEbus backplane, allowing the chip to perform application process control through the VMEbus host. High level C language functions hide details of the hardware system interface from the applications level programmer. The first version of the board was installed on a robot at Oak Ridge National Laboratory in January of 1990.

Symon, James R.↗
NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗
NASA NTRS2000

Effects of microgravity on vestibular development and function in rats: genetics and environment

Our anatomical and behavioral studies of embryonic rats that developed in microgravity suggest that the vestibular sensory system, like the visual system, has genetically mediated processes of development that establish crude connections between the periphery and the brain. Environmental stimuli also regulate connection formation including terminal branch formation and fine-tuning of synaptic contacts. Axons of vestibular sensory neurons from gravistatic as well as linear acceleration receptors reach their targets in both microgravity and normal gravity, suggesting that this is a genetically regulated component of development. However, microgravity exposure delays the development of terminal branches and synapses in gravistatic but not linear acceleration-sensitive neurons and also produces behavioral changes. These latter changes reflect environmentally controlled processes of development.

manned↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human‐rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30‐sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post‐processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one‐way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, Tracie↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, T.↗
NASA NTRS1992

Data management for JGOFS: Theory and design

The Joint Global Ocean Flux Study (JGOFS), currently being organized under the auspices of the Scientific Committee for Ocean Research (SCOR), is intended to be a decade long internationally coordinated program. The main goal of JGOFS is to determine and understand on a global scale the processes controlling the time-varying fluxes of carbon and associated biogenic elements in the ocean and to evaluate the related exchanges with the atmosphere, sea floor and continental boundaries. 'A long-term goal of JGOFS will be to establish strategies for observing, on long time scales, changes in ocean biogeochemical cycles in relation to climate change'. Participation from a large number of U.S. and foreign institutions is expected. JGOFS investigators have begun a set of time-series measurements and global surveys of a wide variety of biological, chemical and physical quantities, detailed process-oriented studies, satellite observations of ocean color and wind stress and modeling of the bio-geochemical processes. These experiments will generate data in amounts unprecedented in the biological and chemical communities; rapid and effortless exchange of these data will be important to the success of JGOFS.

Flierl, Glenn R.↗
NASA NTRSDate not supplied

An Open-Source Numerical Model for Mitigating Refractory Alloy Hot Cracking Susceptibility

Refractory alloys are susceptible to solidification cracking during welding and 3D printing. Composition control is an effective method of controlling solidification cracking. This work evaluates the effect of compositional variation in refractory metal systems on a computed solidification cracking susceptibility. A numerical model has been developed using Python code and open-source CALPHAD software to calculate Kou’s crack susceptibility index. The model is validated against past weldability studies performed on several refractory alloy systems. The approach is extended towards the development of new alloys with improved 3D printability and weldability and is shown to have utility in defining compositional limits for existing alloys and feedstocks. Furthermore, the model will aid in determining process controls for powder reuse and recycling.

pycalphad↗
NASA NTRS1980

LAMMR world data base documentation support and demonstrations

The primary purpose of the World Surface Map is to provide the LAMMR subsystem with world surface type classifications that are used to set up LAMMR LEVEL II process control. This data base will be accessed solely by the LAMMR subsystem. The SCATT and ALT subsystems will access the data base indirectly through the T sub b (Brightness Temperature) Data Bank, where the surface types were updated from a priori to current classification, and where the surface types were organized on an orbital subtrack basis. The single most important factor in the design of the World Surface Maps is the ease of access to the information while the complexity of generating these maps is of lesser importance because their generation is a one-time, off-line process. The World Surface Map provides storage of information with a resolution of 7 km necessary to set flags concerning the earth's features with a different set of maps for each month of the year.

Chin, R.↗
NASA NTRS1993

Repository-Based Software Engineering Program: Working Program Management Plan

Repository-Based Software Engineering Program (RBSE) is a National Aeronautics and Space Administration (NASA) sponsored program dedicated to introducing and supporting common, effective approaches to software engineering practices. The process of conceiving, designing, building, and maintaining software systems by using existing software assets that are stored in a specialized operational reuse library or repository, accessible to system designers, is the foundation of the program. In addition to operating a software repository, RBSE promotes (1) software engineering technology transfer, (2) academic and instructional support of reuse programs, (3) the use of common software engineering standards and practices, (4) software reuse technology research, and (5) interoperability between reuse libraries. This Program Management Plan (PMP) is intended to communicate program goals and objectives, describe major work areas, and define a management report and control process. This process will assist the Program Manager, University of Houston at Clear Lake (UHCL) in tracking work progress and describing major program activities to NASA management. The goal of this PMP is to make managing the RBSE program a relatively easy process that improves the work of all team members. The PMP describes work areas addressed and work efforts being accomplished by the program; however, it is not intended as a complete description of the program. Its focus is on providing management tools and management processes for monitoring, evaluating, and administering the program; and it includes schedules for charting milestones and deliveries of program products. The PMP was developed by soliciting and obtaining guidance from appropriate program participants, analyzing program management guidance, and reviewing related program management documents.

Source record↗
NASA NTRS2019

Reusing Data and Metadata to Create New Metadata Through Machine-Learning & Other Programmatic Methods

Recent improvements in natural language processing (NLP) enable metadata to be created programmatically from reused original metadata or even the dataset itself. Transfer-learning applied to NLP has greatly improved performance and reduced training data requirements. In this talk, we’ll compare machine-generated metadata to human-generated metadata and discuss characteristics of metadata and data archives that affect suitability for machine-learning reuse of metadata. Where as human-generated metadata is often populated once, populated from the perspective of data supplier, populated by many individuals with different words for the same thing, and limited in length, machine-generated metadata can be updated any number of times, generated from the perspective of any user, constrained to a standardized set of terms that can be evolved over time, and be any length required. Machine-learning generated metadata offers benefits but also additional needs in terms of version control, process transparency, human-computer interaction, and IT requirements. As a successful example, we’ll discuss how a dataset of abstracts and associated human-tagged keywords from a standardized list of several thousand keywords were used to create a machine-learning model that predicted keyword metadata for open-source code projects on code.nasa.gov. We’ll also discuss a less successful example from data.nasa.gov to show how data archive architecture and characteristics of initial metadata can be strong controls on how easy it is to leverage programmatic methods to reuse metadata to create additional metadata.

Gosses, Justin↗
DOE OSTI2025

RLGBS: Reinforcement Learning-Guided Beam Search for process optimization in a paper machine dryer section

Paper drying is responsible for over two-thirds of energy consumption in the U.S. pulp and paper industry, presenting significant potential for energy savings through optimization of process parameters. Current approaches often assume fixed operating conditions, neglecting dynamic ambient and process variations that limit achievable savings and real-world applicability. To this end, we develop a physics-based simulation environment for a paper machine dryer section and propose a reinforcement learning (RL) framework to minimize overall energy consumption by optimizing drying process parameters under diverse operating conditions. To mitigate overdrying and numerical instabilities caused by suboptimal local RL actions, we introduce Reinforcement Learning-Guided Beam Search (RLGBS), which explores multiple action sequences in parallel using beam search. Instead of making step-by-step decisions, RLGBS prioritizes solutions based on cumulative probability, reducing the impact of individual suboptimal actions. Experiments demonstrate that RLGBS achieves consistent energy savings under unseen operating conditions not encountered during training, outperforming conventional RL methods. While validated in drying optimization, this framework is broadly applicable to other RL-based industrial process control problems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

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↗
NASA NTRS2003

High Resistivity Transparent/Conductive Coatings for Space Applications: Problems and Possible Improvements

We have prepared transparent films with a sheet relativity of 10(exp 1) to 10(exp 12) ohm/square by co-depositing a transparent conducting oxide (TCO) with magnesium fluoride, using two independently controlled RF magnetron sputter guns to facilitate adjustment of the film composition, Co-deposited indium tin oxide (ITO) and MgF2 on quartz and flexible polymeric substrate exhibited reasonably stable sheet resistivity over several months' time, with substantially lower optical reflectance than that of pure ITO. However, exposure to low-intensity blue light reduces sheet resistivity by as much as two orders of magnitude. Our results suggest this photoconductivity effect may be present in all InO(x)-based materials. We find that sheet resistivity can by "tuned" by admitting a small amount of high-purity air during deposition offering the possibility of closed loop process control.

Cashman, Thomas↗
DOE OSTI2024

Bridging length scales in hard materials with ultra-small angle X-ray scattering – a critical review

Owing to their exceptional properties, hard materials such as advanced ceramics, metals and composites have enormous economic and societal value, with applications across numerous industries. Understanding their microstructural characteristics is crucial for enhancing their performance, materials development and unleashing their potential for future innovative applications. However, their microstructures are unambiguously hierarchical and typically span several length scales, from sub-ångstrom to micrometres, posing demanding challenges for their characterization, especially for in situ characterization which is critical to understanding the kinetic processes controlling microstructure formation. This review provides a comprehensive description of the rapidly developing technique of ultra-small angle X-ray scattering (USAXS), a nondestructive method for probing the nano-to-micrometre scale features of hard materials. USAXS and its complementary techniques, when developed for and applied to hard materials, offer valuable insights into their porosity, grain size, phase composition and inhomogeneities. We discuss the fundamental principles, instrumentation, advantages, challenges and global status of USAXS for hard materials. Using selected examples, we demonstrate the potential of this technique for unveiling the microstructural characteristics of hard materials and its relevance to advanced materials development and manufacturing process optimization. We also provide our perspective on the opportunities and challenges for the continued development of USAXS, including multimodal characterization, coherent scattering, time-resolved studies, machine learning and autonomous experiments. Our goal is to stimulate further implementation and exploration of USAXS techniques and inspire their broader adoption across various domains of hard materials science, thereby driving the field toward discoveries and further developments.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Improved ablative materials for the ASRM nozzle

Rayon precursor carbon-cloth phenolic was developed more than 30 years ago and is used in most nozzles today including the Poseidon, Trident, Peacekeeper, Small ICBM, Space Shuttle, and numerous tactical and space systems. Specifications and manufacturing controls were placed on these materials and, once qualified, a no-change policy was instituted. The current material is acceptable; however, prepreg variability does not always accommodate the requirements of automation. The advanced solid rocket motor requires material with less variability for automated manufacturing. An advanced solid rocket motor materials team, composed of NASA, Thiokol, Aerojet, SRI, and Lockheed specialists, along with materials suppliers ICI Fiberite/Polycarbon, BP Chemicals/Hitco, and Amoco, embarked on a program to improve the current materials. The program consisted of heat treatment studies and standard and low-density material improvements evaluation. Improvements evaluated included fiber/fabric heat treatments, weave variations, resin application methods, process controls, and monitors.

Canfield, A.↗
NASA NTRS1997

Data Base for CFD Validation

The flow behind the shock wave formed around objects which fly at hypervelocity behaves differently from that of a perfect gas. Molecules become vibrationally excited, dissociated, and ionized. The hot gas may emit or absorb radiation. When the atoms produced by dissociation reach the wall surface, chemical reactions, including recombination, may occur. The thermochemical phenomena of vibration, dissociation, ionization, surface chemical reaction, and radiation are referred to commonly as high-temperature real-gas phenomena. The phenomena cause changes in the dynamic behavior of the flow and the surface pressure and heat transfer distribution around the object. The character of a real gas is described by the internal degrees of freedom and state of constituent molecules; nitrogen and oxygen for air. The internal energy states, rotation, vibration and electronic, of the molecules are excited and, in the limit, the molecular bonds are exceeded and the gas dissociated into atomic and, possibly, ionic constituents. The process of energy transfer causing excitation, dissociation and recombination is a rate process controlled by particle collisions. Binary, two-body, collisions are sufficient to cause internal excitation, dissociation and ionization while three-body collisions are required to recombine the particles into molecular constituents. If the rates of energy transfer are fast with respect to the local fluid dynamic time scale the gas is in, or nearly in, equilibrium. If the energy transfer rates are very slow the gas can be described as frozen. In all other instances, wherein any of the energy exchange rates are comparable to the local fluid time scale, the gas will be thermally or chemically reacting and out of equilibrium. Real gas thermochemical nonequilibrium processes are important in the determination of aerodynamic heating; both convective (including wall catalytic effects) and radiative heating. To illustrate this we consider the hypervelocity flow over a bluff body typical of an atmospheric entry vehicle or an aerospace transfer vehicle (ASTV). The qualitative aspects of a hypersonic flow field over a bluff body are discussed in two parts, forebody and afterbody, with attention to which particular physical effects must be included in an analysis. This will indicate what type of numerical modeling will be adequate in each region of the flow. A bluff forebody flow field is dominated by the presence of the strong bow shock wave and the consequent heating, and chemical reaction of the gas. At high altitude hypersonic flight conditions the thermal excitation and chemical reaction of the gas occur slowly enough that a significant portion of the flow field is in a state of thermochemical nonequilibrium. A second important effect is the presence of the thick boundary layer along the forebody surface. In this region there are large thermal and chemical species gradients due to the interaction of the gas with the wall. Also at high altitudes the shock wave and the boundary layer may become so thick that they merge; in this case the entire shock layer is dominated by viscous effects.

Deiwert, George S.↗
NASA NTRS2006

Direct Imaging of Stellar Surfaces: Results from the Stellar Imager (SI) Vision Mission Study

The Stellar Imager (SI) is a UV-Optical, Space-Based Interferometer designed to enable 0.1 milli-arcsecond (mas) spectral imaging of stellar surfaces and stellar interiors (via asteroseismology) and of the Universe in general. SI is identified as a "Flagship and Landmark Discovery Mission'' in the 2005 Sun Solar System Connection (SSSC) Roadmap and as a candidate for a "Pathways to Life Observatory'' in the Exploration of the Universe Division (EUD) Roadmap (May, 2005). The ultra-sharp images of the Stellar Imager will revolutionize our view of many dynamic astrophysical processes: The 0.1 mas resolution of this deep-space telescope will transform point sources into extended sources, and snapshots into evolving views. SI's science focuses on the role of magnetism in the Universe, particularly on magnetic activity on the surfaces of stars like the Sun. SI's prime goal is to enable long-term forecasting of solar activity and the space weather that it drives in support of the Living With a Star program in the Exploration Era. SI will also revolutionize our understanding of the formation of planetary systems, of the habitability and climatology of distant planets, and of many magneto-hydrodynamically controlled processes in the Universe. In this paper we will discuss the results of the SI Vision Mission Study, elaborating on the science goals of the SI Mission and a mission architecture that could meet those goals.

Carpenter, Kenneth↗