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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 73 records · Page 4

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NASA NTRS1999

SPARCLE Optical System Design and Operational Characteristics

The SPAce Readiness Coherent Lidar Experiment (SPARCLE) is the first demonstration of a coherent Doppler wind lidar in space. SPARCLE will be flown aboard a space shuttle In the middle part of 2001 as a stepping stone towards the development and deployment of a long-life-time operational instrument in the later part of next decade. SPARCLE is an ambitious project that is intended to evaluate the suitability of coherent lidar for wind measurements, demonstrate the maturity of the technology for space application, and provide a useable data set for model development and validation. This paper describes the SPARCLE's optical system design, fabrication methods, assembly and alignment techniques, and its anticipated operational characteristics. Coherent detection is highly sensitive to aberrations in the signal phase front, and to relative alignment between the signal and the local oscillator beams. Consequently, the performance of coherent lidars is usually limited by the optical quality of the transmitter/receiver optical system. For SPARCLE having a relatively large aperture (25 cm) and a very long operating range (400 km), compared to the previously developed 2-micron coherent lidars, the optical performance requirements are even more stringent. In addition with stringent performance requirements, the physical and environment constraints associated with this instrument further challenge the limit of optical fabrication technologies.

Amzajerdian, Farzin↗

NASA NTRS1979

Space fabrication demonstration system, technical volume

The automatic beam builder ABB was developed, fabricated, and demonstrated within the established contract cost and schedule constraints. The ABB demonstrated the feasibility of: producing lightweight beams automatically within the required rate of 1 to 5 ft of completed beam per minute and producing structurally sound beams with axial design load of 5538 N based on the Grumman photovoltaic satellite solar power system design reference structure.

Source record↗

NASA NTRS1982

Development of an LSI maximum-likelihood convolutional decoder for advanced forward error correction capability on the NASA 30/20 GHz program

The particular coding option identified as providing the best level of coding gain performance in an LSI-efficient implementation was the optimal constraint length five, rate one-half convolutional code. To determine the specific set of design parameters which optimally matches this decoder to the LSI constraints, a breadboard MCD (maximum-likelihood convolutional decoder) was fabricated and used to generate detailed performance trade-off data. The extensive performance testing data gathered during this design tradeoff study are summarized, and the functional and physical MCD chip characteristics are presented.

Clark, R. T.↗

NASA NTRS1980

Economical space power systems

A commercial approach to design and fabrication of an economical space power system is investigated. Cost projections are based on a 2 kW space power system conceptual design taking into consideration the capability for serviceability, constraints of operation in space, and commercial production engineering approaches. A breakdown of the system design, documentation, fabrication, and reliability and quality assurance estimated costs are detailed.

Burkholder, J. H.↗

DOE OSTI2026

Physicochemical properties of digital light processing 3D-Printed alumina and mullite ceramics

Alumina ceramics fabricated using conventional techniques such as uniaxial pressing or injection molding are popular due to their low density, excellent insulation, and mechanical properties. However, these methods often limit the fabrication of complex geometries with high dimensional accuracy due to tooling constraints and limited design freedom. To overcome these limitations, this study employed Digital Light Processing (DLP) additive manufacturing (AM), which enables the production of precise structures. In addition, the optimization of sintering parameters to enhance the densification and performance of alumina and mullite ceramics was investigated, with a specific focus on how varying sintering temperatures and hold times affect part shrinkage, geometric accuracy, and material integrity. Flexural strength of both alumina and mullite specimens was clearly influenced by the way the layers was stacked. When layers were arranged across the direction of the applied load (Z = 4; XZ), the strength was higher than when they were stacked along the same direction as the load (Z = 3; XY). Weibull analysis based on these results showed high modulus values across all samples, indicating good reliability in the flexural strength measurements. This reliability, combined with the clear influence of sintering parameters, highlights how processing conditions effect the material properties and mechanical performance of parts produced through DLP additive manufacturing. In conclusion, these findings open new avenues for ceramic AM across various applications, enhancing the potential for innovation in fields such as aerospace, biomedical engineering, and energy.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Exploring electron beam induced atomic assembly via reinforcement learning in a molecular dynamics environment

We report atom-by-atom assembly of functional materials and devices is perceived as one of the ultimate targets of nanotechnology. Recently it has been shown that the beam of a scanning transmission electron microscope can be used for targeted manipulation of individual atoms. However, the process is highly dynamic in nature rendering control difficult. One possible solution is to instead train artificial agents to perform the atomic manipulation in an automated manner without need for human intervention. As a first step to realizing this goal, we explore how artificial agents can be trained for atomic manipulation in a simplified molecular dynamics environment of graphene with Si dopants, using reinforcement learning. We find that it is possible to engineer the reward function of the agent in such a way as to encourage formation of local clusters of dopants under different constraints. This study shows the potential for reinforcement learning in nanoscale fabrication, and crucially, that the dynamics learned by agents encode specific elements of important physics that can be learned.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRS1978

Analysis and assessment of film materials and associated manufacturing processes for a solar sail

Candidate resin manufacturers and film producers were surveyed to determine the availability of key materials and to establish the capabilities of fabricators to prepare ultrathin films of these materials within the capacity/cost/time constraints of the Halley program. Infrared spectra of three candidate samples were obtained by pressing each sample against an internal reflection crystal with the polymer sandwiched between the crystal and the metal backing. The sample size was such that less than one-fourth of the surface of the crystal was covered with the sample. This resulted in weak spectra requiring a six-fold expansion. Internal reflection spectra of the three samples were obtained using both a KRS-5 and a Ge internal reflection crystal. Subtracted infrared spectra of the three samples are presented.

Bradbury, E. J.↗

NASA NTRS1978

Spacelab development and its operational verification

This paper gives a brief status report on the current Spacelab program and describes how the results of ground and flight tests will be combined to provide the operational verification of the system. For the on-going project, data on design, testing and fabrication plans are presented. In particular, recent changes to meet the constraints of a 'build-to-cost' project are described. In the operational verification of Spacelab, ground and flight tests which ESA and NASA will perform are addressed. The installation of test instrumentation and the performance of integrated tests will be accomplished in the US. Experiments for the first flight will be integrated into Spacelab racks and pallets and simulated mission tests performed. On-orbit, system thermal surveys are planned and stress data will be obtained during launch and re-entry.

Bignier, M.↗

NASA NTRS2002

The X-ray Mirrors for the Astro-E2 Mission

The X-Ray telescopes (XRT) for the US/Japan collaborative mission Astro-E2 will be of the same basic design as those built for the original Astro-E mission which failed to reach orbit in Feb. 2000. The NASA/GSFC X-ray Astrophysics Branch will again provide the five lightweight, broad-band mirrors for the mission. X-ray calibrations of the mirrors delivered for the original Astro-E instrument showed spatial resolutions characterized by Half-Power Diameters (HPD) in the range of 1.8 - 2.2 minutes of arc, essentially independent of photon energy in the soft X-ray band. For the mission Astro-E2, both funding constraints and management decisions drastically limit any design modifications, so reflector fabrication and assembly procedures have remained largely unchanged. Nevertheless, in view of the importance in scientific return of attaining even a modest improvement in the spatial resolution of these mirrors, we have carefully considered the various sources of spatial error and, whenever possible, incorporated promising modifications. In this paper, we discuss our current understanding of the various error components as well as the small changes we have been able to implement.

Chan, Kai-Wing↗

NASA NTRS2007

Low Velocity Airdrop Tests of an X-38 Backup Parachute Design

The NASA Johnson Space Center's X-38 program designed a new backup parachute system to recover the 25,000 lb X-38 prototype for the Crew Return Vehicle spacecraft. Due to weight and cost constraints, the main backup parachute design incorporated rapid and low cost fabrication techniques using off-the-shelf materials. Near the vent, the canopy was constructed of continuous ribbons, to provide more damage tolerance. The remainder of the canopy was a constructed with a continuous ringslot design. After cancellation of the X-38 program, the parachute design was resized, built, and drop tested for Natick Soldiers Center's Low Velocity Air Drop (LVAD) program to deliver cargo loads up to 22,000 lbs from altitudes as low as 500 feet above the ground. Drop tests results showed that the 500-foot LVAD parachute deployment conditions cause severe skirt inversion and inflation problems for large parachutes. The bag strip occurred at a high angle of attack, causing skirt inversion before the parachute could inflate. The addition of a short reefing line prevented the skirt inversion. Using a lower porosity in the vent area, than is normally used in large parachutes, improved inflation. The drop testing demonstrated that the parachute design could be refined to meet the requirements for the 500-foot LVAD mission.

Stein, Jenny M.↗

NASA NTRS1995

(abstract) Unidirectional Carbon/Carbon for Ion Engine Optics

Conventional ion engine optical grids are made from hydroformed molybdenum. Carbon/carbon has been utilized in place of molybdenum because of its lower sputter yield, which contributes a greatly increased engine life, and for its low cte, which allows more efficient engine operation. The requirements for this material are that it must have high stiffness, very tight dimensional tolerances, and can be optimized for an hexagonal hole pattern with a very high open area friction. The carbon/carbon for this application was fabricated from unidirectional tape prepreg, using pitch fiber, and was processed to a very high temperature. The use of unidirectional tape allowed for a sufficient number of plies to be used to generate a balanced three directional layup within the thickness constraints of the material, as well as providing strength and stiffness over that normally seen with fabric based carbon/carbons.

ion engine carbon/carbon unidirectional tape prepr↗

DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

Global battery manufacturers are increasingly worried about the serious supply chain constraint caused by rapid fluctuations in cobalt prices over the years. We present a novel cobalt-free, nickel-rich layered cathode material called NFA class (LiNixFeyAlzO2) to tackle this challenge. Spherical NFA(OH)2 precursors were successfully synthesized by incorporating Ni, Fe, and Al elements using a co-precipitation reaction in a continuous stirred tank reactor. The LiNFAO2 cathode, composed of LiNi0.85Fe0.05Al0.1O2, was synthesized and analyzed using X-Ray diffraction, Mössbauer spectroscopy, and scanning electron microscopy (SEM). The material's electrochemical behavior was evaluated through various techniques at different lithiation/delithiation states in two voltage ranges. The cobalt-free material exhibits a high capacity of 190 mAh/g at 0.1C within the voltage range of 3V-4.5V, as demonstrated by electrochemical performance evaluations. Rate and cycling evaluations showed good rate capability and cycling stability, with 88% capacity retention after 100 cycles at C/3 within the voltage range of 3V-4.3V. Our research shows the great potential of cobalt-free NFA cathodes as a feasible option for developing cost-effective lithium-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

25 ENERGY STORAGE↗

DOE OSTI2025

A Computational Framework to design 3D stiffness gradient acoustic metamaterials for impedance matching

Acoustic waves play a crucial role in various applications, including medical imaging, non-destructive testing, and sonar systems. One of the significant challenges in these applications is impedance matching, which is essential for minimizing reflections and maximizing the transfer of acoustic energy between different media. Acoustic metamaterials offer a promising solution to this challenge. In addition to impedance control, gradient stiffness can enhance structural efficiency and enable spatial control of wave propagation, making it a valuable feature in acoustic metamaterial design. In this pa- per, we present our developed computational method to design 3D stiffness gradient acoustic metamaterials for impedance matching. The key steps in our approach include generating initial designs using a periodic covariance function to provide unit cells that are both periodic on the boundaries and randomly formed inside the unit cell. Furthermore, we integrated manufacturing constraints into the design process, ensuring that the structures are interconnected for fabrication. We propose two computational optimization algorithms: GenUnit, based on a non-dominated sorting genetic algorithm (NSGA-II), and MLMatch, which leverages differentiable machine learning. The two approaches are not separate contributions but complementary com- ponents of a unified framework. GenUnit requires no training data and directly interfaces with physics-based simulations, making it highly accurate but slower for large-scale exploration. In contrast, MLMatch is data-hungry during training but, once trained, enables near-instantaneous inference and broad design-space coverage. Together, they form a hybrid strategy: ML- Match rapidly explores the global design space, and GenUnit provides local refinement with high-fidelity accuracy. This balance between training cost, inference time, and precision is the motivation for including both methods in the same study. We applied this dual-algorithm framework to generate two metallic-based metamaterial designs that match the acoustic impedance of water while exhibiting a controlled gradient in stiffness (from stiff to soft). The stiffness gradient is particularly advantageous in applications where one side of the structure must interface with soft or sensitive surfaces, such as human tissue or delicate components. Here, this work paves the way for improved materials in various acoustic applications, particularly in ultrasound devices, by providing better impedance.

Metamaterial↗

DOE OSTI2024

Lamination of >21% Efficient Perovskite Solar Cells with Independent Process Control of Transport Layers and Interfaces

Transport layer and interface optimization is critical for improving the performance and stability of perovskite solar cells (PSCs) but is restricted by the conventional fabrication approach of sequential layer deposition. While the bottom transport layer is processed with minimum constraints, the narrow thermal and chemical stability window of the halide perovskite (HP) layer severely restricts the choice of top transport layer and its processing conditions. To overcome these limitations, we demonstrate lamination of HPs—where two transport layer-perovskite half-stacks are independently processed and diffusion-bonded at the HP-HP interface—as an alternative fabrication strategy that enables self-encapsulated solar cells. Power conversion efficiencies (PCE) of >21% are realized using cells that incorporate a novel transport layer combination along with dual-interface passivation via self-assembled monolayers, both of which are uniquely enabled by the lamination approach. This is the highest reported PCE for any laminated PSC encapsulated between glass substrates. We further show that this approach expands the processing window beyond traditional fabrication processes and is adaptable for different transport layer compositions. The laminated PSCs retained >75% of their initial PCE after 1000 h of 1-sun illumination at 40 °C in air using an all-inorganic transport layer configuration without additional encapsulation. Furthermore, a laminated 1 cm 2 device maintained a V oc of 1.16 V. Finally, the scalable lamination strategy in this study enables the implementation of new transport layers and interfacial engineering approaches for improving performance and stability.

14 SOLAR ENERGY↗

NASA NTRS1978

Design and test of a squeeze-film damper for a flexible power transmission shaft

For a flexible shaft designed to pass through a number of bending critical speeds, a squeeze-film damper has been designed and tested. The damper properties were selected to provide control of all critical speeds, while meeting additional constraints of high power transmission requirements and damper simplicity. The damper was fabricated and installed and its ability to control flexible shaft vibrations was demonstrated by the comparison of vibration amplitudes both with and without the damper.

Darlow, M. S.↗

NASA NTRS2003

AM03-AM121-115 Hard X-Ray Optics Development at MSFC

We have developed the electroformed-nickel replication process to enable us to fabricate light-weight hard-x-ray region. Two projects currently utilizing this technology are the production of over 250 r from 5 to 10 cm, for our HERO balloon payload, and 15- and 23-cm-diameter shells for a prototype module. The challenge for the former is to fabricate, mount, align and fly a large number of high-r constraints of a modest budget. For the latter, the challenge is to maintain high angular resolution shell thicknesses (100 micron) which make the shells extremely sensitive to electroforming stresses process does not degrade the ultra-smooth surface finish (approx. 3 A required for eventual multilayer c on these two programs.

Ramsey, Brian↗

NASA NTRS2012

Toward Active X-ray Telescopes II

In the half century since the initial discovery of an astronomical (non-solar) x-ray source, the sensitivity for detection of cosmic x-ray sources has improved by ten orders of magnitude. Largely responsible for this dramatic progress has been the refinement of the (grazing-incidence) focusing x-ray telescope. The future of x-ray astronomy relies upon the development of x-ray telescopes with larger aperture areas (greater than 1 m2) and finer angular resolution (less than 1.). Combined with the special requirements of grazing-incidence optics, the mass and envelope constraints of space-borne telescopes render such advances technologically challenging.requiring precision fabrication, alignment, and assembly of large areas (greater than 100 m2) of lightweight (approximately 1 kg m2 areal density) mirrors. Achieving precise and stable alignment and figure control may entail active (in-space adjustable) x-ray optics. This paper discusses relevant programmatic and technological issues and summarizes progress toward active x-ray telescopes.

O'Dell, Stephen L.↗