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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Can advanced technology improve future commuter aircraft

The short-haul service abandoned by the trunk and local airlines is being picked up by the commuter airlines using small turboprop-powered aircraft. Most of the existing small transport aircraft currently available represent a relatively old technology level. However, several manufacturers have initiated the development of new or improved commuter transport aircraft. These aircraft are relatively conservative in terms of technology. An examination is conducted of advanced technology to identify those technologies that, if developed, would provide the largest improvements for future generations of these aircraft. Attention is given to commuter aircraft operating cost, aerodynamics, structures and materials, propulsion, aircraft systems, and technology integration. It is found that advanced technology can improve future commuter aircraft and that the largest of these improvements will come from the synergistic combination of technological advances in all of the aircraft disciplines. The most important goals are related to improved fuel efficiency and increased aircraft productivity.

Williams, L. J.↗
DOE OSTI2023

2022 Annual Report Laboratory Directed Research & Development

Idaho National Laboratory’s (INL’s) mission is “to discover, demonstrate and secure innovative nuclear energy solutions, other clean energy options and critical infrastructure.” INL executes this mission through research and development across the continuum from basic science to applied science to engineering demonstration and then deployment. The Department of Energy (DOE) Laboratory Directed Research and Development (LDRD) program enables INL to conduct high-risk, impactful research that enriches the laboratory capabilities in order to further its missions. INL’s LDRD portfolio specifically advances the core capabilities of the laboratory aligned with its five science and technology initiatives: 1) nuclear reactor sustainment and expanded deployment, 2) integrated fuel cycle solutions, 3) integrated energy systems, 4) advanced design and manufacturing for extreme environments, and 5) secure and resilient cyber-physical systems. The 45 projects that ended in fiscal year 2022 and highlighted in this report are just a small sample of the impressive breadth and depth of cutting-edge science, technology, and engineering ongoing at INL.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Enhancement of Carbon Capture Reactor Performance (Final Technical Report)

Significant challenges are still present in post-combustion CO 2 capture and new technologies and advanced components are needed to significantly advance the deployment of CO 2 capture for natural gas combined cycle (NGCC) plants. Critical elements of CO 2 capture that still need to be addressed include how to increase CO 2 mass transfer in the absorber column with liquid to gas ratios of <1.2, while reducing the size of the absorber column to reduce capital costs. Research involving chemical mechanism with design, synthesis, and assembly of materials with targeted functionally were combined with advanced additive manufacturing techniques towards development of enhanced CO 2 capture reactors that can lead to safe, reliable, and low-cost carbon capture technologies. The objective of the project was to develop and test novel carbon capture materials and reactor components that contribute to increased CO 2 mass transfer through increased turbulent gas-liquid interface and improved solvent wetting within the absorber. A technoeconomic analysis (TEA) was completed showing how the proposed technology decreases capital costs by reducing the size of the absorber column and the amount of packing required for high CO 2 capture rates. A technology maturation plan (TMP) was also developed to describe the current technology readiness levels (TRL) and outline additional research and development (R&D) needed to further develop these advanced components for NGCC CO 2 capture plants. The successful completion of this project has shown a pathway to reduce the absorber size and associated construction costs of post-combustion NGCC CO 2 capture systems at 97% capture and promote the utilization of abundant natural gas for production of reliable electricity.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRSDate not supplied

OSAM-2: Plans and Progress for the First Demonstration of Structural Manufacturing in Space

OSAM-2 began as a NASA Space Technology Mission Directorate Tipping Point project in 2016 in which an investment made in ground development and demonstration and/or flight demonstration will result in: Significant advancement of technology’s maturation High likelihood for utilization of technology in commercially fielded space application Significant improvement in ability to successfully bring space technology to market Topic area was “Robotic In-Space Manufacturing and Assembly of Spacecraft and Space Structures” Made In Space, Inc. (now Redwire) proposed Archinaut One, an in-space robotic precision manufacturing and assembly system for larger-than-deployable structures Manufacturing / assembly in the operational environment allows manufactured parts to be designed for that environment (and not for launch loads and need to deploy) In 2020 NASA budget language, NASA began using On-orbit Servicing, Assembly, and Manufacturing Mission 2 (OSAM-2) for Archinaut One Restore-L + SPIDER (SPace Infrastructure DExterous Robot) became OSAM-1 Note: Slide 7 contains video animation, best viewed in presentation mode, run time 2 mins 25 secs.

In-Space Manufacturing↗
NASA NTRS1976

Foreign civil aviation competition: 1976 summary and implications

A summary assessment is made of foreign civil aviation as it relates to the posture of the United States civil aviation industry. Major findings include: (1) Main competitors - European Economic Community (EEC) and Union of Soviet Socialist Republics (USSR). (2) Largest commercial market - Transport aircraft. (3) Current market status and projections - U.S. currently dominates the civil aviation market but foreign markets show greater growth trends. (4) Competitive comparisons - Status comparisons are made in technology (aerodynamics, structures and materials, propulsion, avionics, systems, design coordination, and manufacturing); production runs; marketing; and postsales support. The U.S. generally leads except in aerodynamics and propulsion. (5) Multinational ventures - Joint U.S. industry/foreign government development of advanced technology engines is well developed; airframe industry discussions are now underway. (6) Implications - Although the U.S., is currently preeminent in most areas, this may be only a temporary condition. Past U.S. success in aviation has provided many benefits to the nation. These benefits may be lost.

Alford, W. J., Jr.↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Extraordinary Accomplishments of the In Space Production Applications Portfolio in 2024

The purpose of the NASA In-Space Production Applications (InSPA) program is to provide funding and expertise to help brilliant United States innovators and businesses traverse the technology “Valley of Death” by proving out their concepts for in-space manufactured materials and products that will ultimately be sold to customers on the Earth. Scientific and technological advances on the International Space Station (ISS) and on Earth coupled with evolving societal needs are collectively enabling InSPA-funded teams to produce data streams and advanced biological, chemical, and physical materials solutions with economic value. We report on an extraordinary year of accomplishments on the ISS and highlight top InSPA and ISS National Lab results that span historic firsts in cancer research, stem cells, crystal production, optical fiber production, drug discovery, in-space treatments with RNA therapeutics, and production of artificial retinas from space. We assert that the results have enormous potential, are transforming the space exploration ecosystem and are the “seeds” of a microgravity industrial revolution that are shaping national microgravity strategy.

in spa↗
NASA NTRS2018

Electrostatic Levitation for Studies of Additive Manufacturing Materials for Extreme Environments

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center (MSFC) is a national resource for researchers developing advanced materials for new technologies. Researchers have used MSFC's ESL Laboratory to develop advanced high-temperature materials for aerospace applications, coatings and structural materials for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials for extreme environments is necessary for the control of their resulting materials properties. Unfortunately, there is very little materials properties data for many additive manufacturing materials, especially of the materials in the liquid state. The MSFC ESL lab is ideal for the study of additive manufacturing materials to be used in extreme environments. The lab can provide density, surface tension, and viscosity of molten materials, emissivity measurements, and even creep strength measurements.

SanSoucie, Michael↗
NASA NTRSDate not supplied

Advanced Materials and Feedstock Development for On-orbit Manufacturing

This presentation is for the On-orbit Servicing, Assembly, and Manufacturing (OSAM) Technology Transfer Workshop. The content discusses materials research done to date, and research that is ongoing, applicable to OSAM applications. The talk includes content from the In-Space Manufacturing and Moon to Mars Planetary Autonomous Construction Technology projects.

On-orbit Servicing Assembly and Manufacturing↗
DOE OSTI2020

Scale-up of Next Generation Nano-Enhanced Composite Materials for Longer Lasting Consumer Goods

The objective for this project was to create an industrial-scale manufacturing operation for Vertically Aligned Carbon Nanotube Forests (VACNTs), which make up N12 Technologies’ (N12) NanoStitch® product, a prepreg additive that makes advanced composites tougher, lighter, and more durable. This was achieved using University of Dayton Research Institute’s (UDRI) 60-inch Nano Adaptive Hybrid Fabric (NAHF-X) reactor system. N12 had a unique and effective nanomaterial-based product that they were manufacturing on small-scale 1-inch wide substrate machines in Boston, MA. UDRI had a large-scale 60-inch wide nanomaterial growth reactor available for scaling up 2nd party products in Dayton, OH. Thanks to the successful cooperation between both parties, this project resulted in the world’s first industrial-scale continuous VACNT film pilot plant in Dayton, OH with an increase in VACNT supply production rate of >10X. This scale up enabled market validation via testing programs and pilot manufacturing operations with a number of customers.

36 MATERIALS SCIENCE↗
NASA NTRS1992

NASA-ACEE/Boeing 737 graphite-epoxy horizontal stabilizer service

The 737 graphite-epoxy horizontal stabilizer was developed by Boeing as part of the NASA-ACEE (Aircraft Energy Efficiency) Advanced Composite Structures Program. NASA-ACEE programs challenged large-transport manufacturers to use graphite material in redesigning existing aircraft components. The goal of the program was to develop the necessary data and technology to achieve production commitments to advanced composites. Boeing designed, fabricated, and certified five shipsets of horizontal stabilizers for the 737-200 airframe. The program was initiated in July 1977 and certification was achieved in August 1982. Schedule highlights are shown. The work performed on this program is reported in NASA technical summaries and final reports. Boeing introduced the stabilizer into commercial operation in 1984, and has maintained surveillance for seven years of in-service evaluation. Outstanding performance was demonstrated with no service incidents attributed to the graphite-epoxy structure. Boeing will continue to monitor and support these aircraft, adding to the database of commercial composite experience.

Quinlivan, J. T.↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Kinetic Monte Carlo for semiconductor surface science v.1

SAND2020-14229 O This software builds on an open source Kinetic Monte Carlo library to evaluate the incorporation rate of semiconductor dopant atoms in an Atomic Precision Advanced Manufacturing (APAM) process. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525

Campbell, Quinn↗
DOE OSTI2021

Electron Linear Accelerator Additive Manufacturing

Superconducting electron linear accelerators open up new opportunities for advanced materials processing. High energy electrons penetrate deeper within materials, increase the processing depth and rate and enables production of far-from-equilibrium materials and selective processing within a material surface and subsurface. With support from the Office of Naval Research, NASA, and DoE, Mainstream Engineering commissioned a superconducting linear electron accelerator to investigate advanced materials processing and additive manufacturing. The goal of Mainstream's Electron Beam Enabled Advanced Manufacturing (EBEAM) center is to develop unique, far-from-equilibrium materials and alleviate significant technological deficiencies. We will present results of irradiating various metals and their unique material properties. Monte Carlo simulations electron beam and sample interaction were used to optimize the processing parameters and study far-from-equilibrium processing conditions. Applications include stainless steel additive manufacturing for small modular nuclear reactors and dissimilar metal bonding of corrosion-resistant cladding for next-generation molten salt reactors.

36 MATERIALS SCIENCE↗
DOE OSTI2023

CalTestBed - OnTo Technology - Characterization of Recycled Cathode and Anode Particles as a Function of Process Step (Final Report)

Onto Technology carries out advanced Li-ion battery recycling for industry and. has the only patented technology to produce manufacturing quality electrode materials from recycled batteries. The technology can resolve ongoing cost problems for the industry in life-cycle and conservation of critical materials. Under the Cal TestBed program, Onto Technology teamed with principal investigators at Lawrence Berkeley National Laboratory, who performed tests to evaluate the electrochemical performance of refurbished electrode materials. Other tests to determine structure and morphology of the refurbished materials carried out at LBNL included X-ray diffraction (XRD) and scanning electron microscopy (SEM).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Los Alamos National Laboratory Director's Strategic Resilience Initiative

The Director’s Strategic Resilience Initiative was created late in 2019 in recognition of the changing geo-political climate. The renewed strategic competition between Russia, China, and the United States, noted in the 2018 National Defense Strategy and the 2018 Nuclear Posture Review, put great power rivalry and competition at the forefront of national security considerations. At the same time, Russian President Vladimir Putin’s March 1, 2018, speech and China’s October 1, 2019, National Day Military Parade, underscored the nuclear dimensions of this new strategic competition. Accompanying this changed strategic environment are rapid advances in an expansive array of relevant technological sectors including affordable and comprehensive global communication and reconnaissance assets, autonomous vehicles, quantum computing, advanced manufacturing, and artificial intelligence.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

The Implications of Advanced Manufacturing in a Connected Economy Moving Towards a Smart, Sustainable, and Productive Economy

This report intends to provide a comprehensive overview of information and communications technologies (ICT), which play increasingly vital roles in the United States (U.S.) and global economies and continue to evolve rapidly as both technological capabilities and needs grow in tandem. To underscore the importance of the sector, the U.S. Congress recently passed a $\$$20–$\$$50 billion federal program Creating Helpful Incentives to Produce Semiconductors Act (CHIPS Act) to spur the competitiveness of the U.S. semiconductor industry and encourage U.S. investment, often complemented by state-level incentives (Kessler 2022).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Advancing Diffusion Bonded Compact Heat Exchangers for High Temperature Applications

Enhancement of the diffusion bonding process for the development of compact heat exchangers (CHXs) provides an energy efficient solution for high-temperature applications in advanced nuclear reactors and other technologies. However, available information is limited concerning the diffusion bonding (and manufacturing) of CHXs in high temperature applications and associated selection of bonded materials, bonding conditions, mechanical performance, and thermo-fluid characteristics. Here this article reviews the available knowledge and the ongoing research being conducted to address gaps in information and application.

36 MATERIALS SCIENCE↗