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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

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

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

Dynamic optimization↗
NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

This paper presents a design automation process using optimization via a genetic algorithm to design the conceptual structure of a Lunar Pallet Lander. The goal is to determine a design that will have the primary natural frequencies at or above a target value as well as minimize the total mass. Several iterations of the process are presented. First, a concept optimization is performed to determine what class of structure would produce suitable candidate designs. From this a stiffened sheet metal approach was selected leading to optimization of beam placement through generating a two-dimensional mesh and varying the physical location of reinforcing beams. Finally, the design space is reformulated as a binary problem using 1-dimensional beam elements to truncate the design space to allow faster convergence and additional mechanical failure criteria to be included in the optimization responses. Results are presented for each design space configuration. The final flight design was derived from these results.

Burt, Adam O.↗
DOE OSTI2024

Advanced Process Control and Dynamic Optimization of Reversible Solid Oxide Cell Systems for Performance and Long-Term Health

This presentation was delivered at the 2024 Hydrogen Annual Merit Review Meeting. It focuses on three aspects of projects focusing on solid oxide cell systems- advanced control including nonlinear model predictive control and traditional control, dynamic optimization with due consideration of chemical degradation over the cell lifetime, dynamic optimization considering physical degradation.

Allan, Douglas↗
NASA NTRS1989

Efficient sensitivity analysis and optimization of a helicopter rotor

Aeroelastic optimization of a system essentially consists of the determination of the optimum values of design variables which minimize the objective function and satisfy certain aeroelastic and geometric constraints. The process of aeroelastic optimization analysis is illustrated. To carry out aeroelastic optimization effectively, one needs a reliable analysis procedure to determine steady response and stability of a rotor system in forward flight. The rotor dynamic analysis used in the present study developed inhouse at the University of Maryland is based on finite elements in space and time. The analysis consists of two major phases: vehicle trim and rotor steady response (coupled trim analysis), and aeroelastic stability of the blade. For a reduction of helicopter vibration, the optimization process requires the sensitivity derivatives of the objective function and aeroelastic stability constraints. For this, the derivatives of steady response, hub loads and blade stability roots are calculated using a direct analytical approach. An automated optimization procedure is developed by coupling the rotor dynamic analysis, design sensitivity analysis and constrained optimization code CONMIN.

Lim, Joon W.↗
NASA NTRS2007

Build-Up Approach to Updating the Mock Quiet Spike Beam Model

When a new aircraft is designed or a modification is done to an existing aircraft, the aeroelastic properties of the aircraft should be examined to ensure the aircraft is flight worthy. Evaluating the aeroelastic properties of a new or modified aircraft can include performing a variety of analyses, such as modal and flutter analyses. In order to produce accurate results from these analyses, it is imperative to work with finite element models (FEM) that have been validated by or correlated to ground vibration test (GVT) data, Updating an analytical model using measured data is a challenge in the area of structural dynamics. The analytical model update process encompasses a series of optimizations that match analytical frequencies and mode shapes to the measured modal characteristics of structure. In the past, the method used to update a model to test data was "trial and error." This is an inefficient method - running a modal analysis, comparing the analytical results to the GVT data, manually modifying one or more structural parameters (mass, CG, inertia, area, etc.), rerunning the analysis, and comparing the new analytical modal characteristics to the GVT modal data. If the match is close enough (close enough defined by analyst's updating requirements), then the updating process is completed. If the match does not meet updating-requirements, then the parameters are changed again and the process is repeated. Clearly, this manual optimization process is highly inefficient for large FEM's and/or a large number of structural parameters. NASA Dryden Flight Research Center (DFRC) has developed, in-house, a Mode Matching Code that automates the above-mentioned optimization process, DFRC's in-house Mode Matching Code reads mode shapes and frequencies acquired from GVT to create the target model. It also reads the current analytical model, as we11 as the design variables and their upper and lower limits. It performs a modal analysis on this model and modifies it to create an updated model that has similar mode shapes and frequencies as those of the target model. The Mode Matching Code output frequencies and modal assurance criteria (MAC) values that allow for the quantified comparison of the updated model versus the target model. A recent application of this code is the F453 supersonic flight testing platform, NASA DFRC possesses a modified F-15B that is used as a test bed aircraft for supersonic flight experiments. Traditionally, the finite element model of the test article is generated. A GVT is done on the test article ta validate and update its FEM. This FEM is then mated to the F-15B model, which was correlated to GVT data in fall of 2004, A GVT is conducted with the test article mated to the aircraft, and this mated F-15B/ test article FEM is correlated to this final GVT.

Herrera, Claudia Y.↗
DOE OSTI2025

Multiscale Characterization of Additive Manufacturing Components with Computed Tomography, 3D X-ray Microscopy, and Deep Learning

Additive manufacturing (AM) facilitates the creation of complex-geometry parts, driving advancements in lightweight aerospace components, high-efficiency engine cooling channels, and customized medical implants. However, ensuring the quality and reliability of AM parts remains challenging due to internal defects, surface irregularities, porosity, and residual trapped powder, which are often inaccessible to traditional inspection methods. Recent developments in X-ray computed tomography (XCT) and 3D X-ray microscopy (XRM), particularly systems equipped with resolution-at-a-distance (RaaD™) capabilities, enable high-resolution, non-destructive evaluation of AM components across multiple scales, from sub-micrometer to macroscopic levels. This paper explores modern XCT and XRM techniques for multiscale characterization of AM parts, focusing on their ability to detect and analyze defects such as porosity, cracks, inclusions, and surface roughness, while offering insights into defect formation mechanisms, material properties, and process-induced variations. The integration of deep learning (DL) frameworks, including Simurgh, DeepRecon, and DeepScout, enhances XCT/XRM workflows by reducing scan times, improving resolution recovery, and enabling accurate defect detection even with limited projection data. These DL-based methods overcome limitations of traditional reconstruction techniques, enabling faster, more reliable characterization of dense materials like Inconel 718 and novel alloys such as AlCe. Applications include process parameter optimization, high-throughput quality control, and multistage AM process evaluation, with DL-enhanced workflows accelerating analysis times from weeks to days. Correlative imaging approaches further validate XCT and XRM data against scanning electron microscopy (SEM) images of physically sectioned samples, confirming the accuracy of DL-based reconstructions and enabling comprehensive defect analysis. While challenges remain in generalizing DL models to diverse materials and imaging conditions, improvements in resolution, noise reduction, and defect detection highlight the transformative potential of these methods. This multiscale and correlative approach enables precise identification and correlation of microstructural features with the overall performance of AM components. By integrating advanced XCT, XRM, and DL techniques, this paper demonstrates a significant leap forward in AM characterization, offering valuable insights into the relationships between processing parameters, microstructure, and part performance, and driving innovations that enhance the quality and reliability of AM products for demanding industrial applications.

Additive manufacturing↗
DOE OSTI2025

PUMA:POWDER UTILIZATION MODELING APPLICATION

SF-25-084 PUMA a high performance modeling framework to simulate powder processing. It provides a scalable tool for manufacturers to simulate powder pre- and post-processing. The tool can predict the distortion, residual stress, and (for reactive processes) reaction completion fraction of complex parts after curing/debinding, sintering, and infiltration processes. These predictions are key metrics industry uses to optimize these processes to produce dense, defect-free, stable components.

HU, TIANCHEN (GARY)↗
NASA NTRS2018

Accessing Data Stored in Amazon S3 Using the Hyrax OPeNDAP Server

For three years we have been investigating data storage and retrieval in the Amazon Cloud, striving to optimize both storage structures and (cache-enhanced retrieval processes. These optimizations are hidden from data users, who simply employ the Data Access Protocol (DAP), a popular, Web-based Application Programmer Interface (API) developed by OPeNDAP. We present our collected findings and their realization in the Hyrax data server. Specific techniques include caching data on spinning disk; accessing sharded data in place; optimizing the organizational structures for data within the flat key-value space of Simple Storage Service (S3); and employing an API extension that permits simultaneous operations on many datasets in a single request.

Data access↗
DOE OSTI2026

Systematic analysis of melt pool dynamics in laser processing of mixed powder feedstocks

Functionally graded materials (FGMs) fabricated via additive manufacturing of blended powders offer the potential to spatially tailor properties for new technologies, such as fusion first-wall systems, turbine blades, and spacecraft. However, processing these materials is difficult due to the multiplicity of processing parameters to optimize, all of which must be changed as substrate material, powder feedstock compositions, and melt pool dynamics evolve. Here, this work systematically evaluates the qualitative and quantitative effects of these variables on the melt pool size, shape, composition, and particle distribution in an exemplar Ti-Ta system, and connects the experimental results to Marangoni flow behavior and phenomena observed in other systems. Increasing laser power linearly increases melt pool size and layer thickness, driving engineering considerations such as part/geometrical tolerances. Decreasing laser velocity changes the melt pool shape from lenticular to convex and reduces chemical homogeneity due to extreme thermal and compositional gradients between the melt pool center and boundaries. Thermophysical property differences between the powder feedstock and substrate material, as well as the directionality of the gradient, affect dilution and melt pool dynamics, which in turn affect the melt pool boundary characteristics, shape, and uniformity. Mixed powder feedstocks of intermediate compositions do not behave according to linear interpolations between single-material endpoints, instead building taller and wider melt pools. As such, it is recommended to quantify process maps for at least one intermediate composition in the FGM or multi-material system of interest to ensure optimized processing parameters, predictable melt pool sizes and shapes, and compositional and spatial precision.

Dissimilar↗
NASA NTRS1990

Image gathering, coding, and processing: End-to-end optimization for efficient and robust acquisition of visual information

Researchers are concerned with the end-to-end performance of image gathering, coding, and processing. The applications range from high-resolution television to vision-based robotics, wherever the resolution, efficiency and robustness of visual information acquisition and processing are critical. For the presentation at this workshop, it is convenient to divide research activities into the following two overlapping areas: The first is the development of focal-plane processing techniques and technology to effectively combine image gathering with coding, with an emphasis on low-level vision processing akin to the retinal processing in human vision. The approach includes the familiar Laplacian pyramid, the new intensity-dependent spatial summation, and parallel sensing/processing networks. Three-dimensional image gathering is attained by combining laser ranging with sensor-array imaging. The second is the rigorous extension of information theory and optimal filtering to visual information acquisition and processing. The goal is to provide a comprehensive methodology for quantitatively assessing the end-to-end performance of image gathering, coding, and processing.

Huck, Friedrich O.↗
DOE OSTI2025

Understanding Structural and Compositional Evolution during NMC Cathode Direct Recycling via Solid-State NMR

Recycling end-of-life lithium-ion batteries (LIBs) to recover high-value cathode materials such as LiNixMnyCozO2 (NMC) is driven by economical, geopolitical, and sustainability needs. There has been recent interest in direct recycling methods to improve efficiency and recovery of materials, including ionothermal, hydothermal, solid-state, or redox mediator methods. In conjunction with recycling process development, detailed structural characterization is necessary in order to understand the mechanisms and efficacy of cathode recycling steps. Solid-state nuclear magnetic resonance (NMR) spectroscopy is a unique tool that can probe Li coordination, bulk and surface environments, and transition metal ordering in recycled and upcycled NMC cathodes. Here, 6,7Li, 1H, and 19F NMR spectroscopy to probe structural and compositional changes as well as surface impurities that may form during each step in NMC direct recycling is utilized. During relithiation, Li reinsertion into the NMC lattice is observed. During upcycling, where the goal is to increase the Ni content in the NMC, incorporation of Ni-rich phases into the bulk Li environment is observed. Surface impurities formed during processing were also identified. These studies provide valuable information for optimizing recycling processes to reach targeted cathode composition and structure that can enable electrochemical performance comparable to or better than pristine materials.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Parametric Cost Analysis: A Design Function

Parametric cost analysis uses equations to map measurable system attributes into cost. The measures of the system attributes are called metrics. The equations are called cost estimating relationships (CER's), and are obtained by the analysis of cost and technical metric data of products analogous to those to be estimated. Examples of system metrics include mass, power, failure_rate, mean_time_to_repair, energy _consumed, payload_to_orbit, pointing_accuracy, manufacturing_complexity, number_of_fasteners, and percent_of_electronics_weight. The basic assumption is that a measurable relationship exists between system attributes and the cost of the system. If a function exists, the attributes are cost drivers. Candidates for metrics include system requirement metrics and engineering process metrics. Requirements are constraints on the engineering process. From optimization theory we know that any active constraint generates cost by not permitting full optimization of the objective. Thus, requirements are cost drivers. Engineering processes reflect a projection of the requirements onto the corporate culture, engineering technology, and system technology. Engineering processes are an indirect measure of the requirements and, hence, are cost drivers.

Dean, Edwin B.↗
NASA NTRS2021

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the-art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts. The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners. However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen Michael Middleton↗
NASA NTRSDate not supplied

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts.1,2 The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners.1 However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen M Middleton↗
NASA NTRSDate not supplied

Materials Informatics at NASA GRC: Machine Learning Surrogate Modeling, Data Management, and Integrated Toolsets for Establishing/Maintaining the Digital Thread

Integrated Computational Materials Engineering (ICME) has recently received widespread attention due to its promises in reducing dependence on physical testing for engineering design by relying on simulation, reducing both time and cost to market for various applications. ICME however requires validated multiscale material models, which heavily depend on available test data with full material and test pedigree, including material processing, test and measurement equipment, raw data collection, and analysis methodology and results that is findable and usable, along with integrated, efficient toolsets for effectively passing information across various length and time scales across such models. At the NASA Glenn Research Center under the Transformational Tools and Technologies Project, significant recent efforts have been directed towards establishing the required cyberinfrastructure to enable optimized ICME processes and the design of “fit-for-purpose” materials to achieve the goals outlined in the NASA Vision 2040 report. Such efforts include development of multiscale physics-based material models, which can be used to train highly efficient surrogate machine learning models, development of best practices and infrastructure for effective, traceable materials information management, and development of toolsets that integrate with physics-based codes, machine learning models, and an information management system to enable high throughput of materials data collection and analysis, establishment of digital twins and the digital thread, and automation of the ICME design process for material optimization.

Machine Learning↗