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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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NASA NTRS1983

X-ray spectrographs using radial groove gratings

A high efficiency spectrograph design for the EUV and soft X rays is presented. This grazing incidence system uses a plane surface reflection grating with rulings that are radial, like the spokes of a wheel. The grating is placed in a beam of light that is converging to a focus. The single reflection off the grating is in the conical diffraction mount ensuring maximum performance from the system. Aberrations and performance levels are discussed. The gratings can be manufactured with existing ruling engines. Sample applications to an X-ray monochromator and an EUV stellar spectrograph are discussed.

Cash, W. C., Jr.↗

NASA NTRS2024

NASA HECC Geometry and Performance Review Part 1: Validation of a Computational Model for the Vaneless Diffuser Configuration with As-Manufactured Impeller Geometry

An investigation of the NASA High Efficiency Centrifugal Compressor (HECC) vaneless diffuser configuration was performed. This multipart investigation presents an extensive validation of the computational model against experimental data. The validated model was then used to explore the effects geometric differences between the as-manufactured and design-intent impellers. Lastly, the validated model was used for comparison against an experimental tip clearance study. Part I of the investigation focused on describing the HECC vaneless computational model and its validation against the experimental data published in GT2023-103128. To generate the model, a verification of the manufactured impeller was performed and was confirmed to match the impeller CAD. Section data from the impeller CAD, referred to as the As-Manufactured geometry, were used for development of the computational model. Steady RANS simulations utilizing the Wilcox K-Omega 98 turbulence model and a multiblock structured mesh were used to conduct a mesh convergence study. The resultant mesh was then used for simulations at both design-speed and off-design speed conditions. The simulations compared well to data in both 1D and 2D terms for the major performance metrics of efficiency, total pressure rise, and total temperature rise. Based on the observed results the model was deemed validated and was used in the latter two parts of the multipart investigation.

centrifugal compressor↗

NASA NTRSDate not supplied

Modified Epoxy Matrix Resins for Reduced Dependence on Redundant Fasteners in Secondary-Bonded Composite Structures

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination that can lead to weak bonds. No methods currently exist to measure the strength of an adhesive bond nondestructively. For these reasons, regulating organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to achieve certification for civil transport aircraft. To meet this requirement, manufacturers commonly install redundant fasteners (~105 fasteners in a twin-aisle airframe with composite fuselage and wings), which add tremendous complexity, time and cost, and significantly reduce performance of the airframe. Under NASA’s Convergent Aeronautics Solutions (CAS) Program, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy matrix resins to enable reflow and diffusion of the resin at the interface during a secondary bonding/cure process. The mixing process eliminates the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion across a nearly two-dimensional boundary. The AERoBOND interface is similar to the interlaminar region formed during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin, which can be measured, inspected non-destructively, and certified for flight with fewer redundant fasteners. This presentation describes the ongoing development of stoichiometrically-offset epoxy resins to control the degree of cure in composite joints and enable interfacial mixing during secondary bonding/curing. Details on the resin formulation, laminate fabrication, and mechanical testing will also be presented. The precracked mode-II fracture toughness measured from preliminary AERoBOND joints was similar for joints fabricated with conventional epoxy matrix materials.

thermoset, hardener, prepreg, assembly↗

DOE OSTI2021

Proton switching molecular magnetoelectricity

Abstract The convergence of proton conduction and multiferroics is generating a compelling opportunity to achieve strong magnetoelectric coupling and magneto-ionics, offering a versatile platform to realize molecular magnetoelectrics. Here we describe machine learning coupled with additive manufacturing to accelerate the design strategy for hydrogen-bonded multiferroic macromolecules accompanied by strong proton dependence of magnetic properties. The proton switching magnetoelectricity occurs in three-dimensional molecular heterogeneous solids. It consists of a molecular magnet network as proton reservoir to modulate ferroelectric polarization, while molecular ferroelectrics charging proton transfer to reversibly manipulate magnetism. The magnetoelectric coupling induces a reversible 29% magnetization control at ferroelectric phase transition with a broad thermal hysteresis width of 160 K (192 K to 352 K), while a room-temperature reversible magnetic modulation is realized at a low electric field stimulus of 1 kV cm −1 . The findings of electrostatic proton transfer provide a pathway of proton mediated magnetization control in hierarchical molecular multiferroics.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites

Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.

Josh Fody↗

DOE OSTI2022

Thermal modeling of directed energy deposition additive manufacturing using graph theory

Purpose: The purpose of this paper is to develop, apply and validate a mesh-free graph theory–based approach for rapid thermal modeling of the directed energy deposition (DED) additive manufacturing (AM) process. Design/methodology/approach: Here, the authors develop a novel mesh-free graph theory–based approach to predict the thermal history of the DED process. Subsequently, the authors validated the graph theory predicted temperature trends using experimental temperature data for DED of titanium alloy parts (Ti-6Al-4V). Temperature trends were tracked by embedding thermocouples in the substrate. The DED process was simulated using the graph theory approach, and the thermal history predictions were validated based on the data from the thermocouples. Findings: The temperature trends predicted by the graph theory approach have mean absolute percentage error of approximately 11% and root mean square error of 23°C when compared to the experimental data. Moreover, the graph theory simulation was obtained within 4 min using desktop computing resources, which is less than the build time of 25 min. By comparison, a finite element–based model required 136 min to converge to similar level of error. Research limitations/implications: This study uses data from fixed thermocouples when printing thin-wall DED parts. In the future, the authors will incorporate infrared thermal camera data from large parts. Practical implications: The DED process is particularly valuable for near-net shape manufacturing, repair and remanufacturing applications. However, DED parts are often afflicted with flaws, such as cracking and distortion. In DED, flaw formation is largely governed by the intensity and spatial distribution of heat in the part during the process, often referred to as the thermal history. Accordingly, fast and accurate thermal models to predict the thermal history are necessary to understand and preclude flaw formation. Originality/value: This paper presents a new mesh-free computational thermal modeling approach based on graph theory (network science) and applies it to DED. The approach eschews the tedious and computationally demanding meshing aspect of finite element modeling and allows rapid simulation of the thermal history in additive manufacturing. Although the graph theory has been applied to thermal modeling of laser powder bed fusion (LPBF), there are distinct phenomenological differences between DED and LPBF that necessitate substantial modifications to the graph theory approach.

42 ENGINEERING↗

DOE OSTI2021

Additive manufacturing system and method having toolpath analysis

An additive manufacturing (AM) system is disclosed for constructing a three dimensional (3D) part with optimized orthotropy. The system combines an electronic processor which calculates an optimal set of physically achievable toolpaths to meet a given design objective, and a 3D printing direct ink write machine capable of printing inks with reinforcing particles that result in orthotropic materials. The electronic processor may combine a Domain of Interest subsystem that transforms a mathematical description of a desired part orthotropy to a plurality of guidepaths, a toolpath generate subsystem that develops a plurality of physically realizable toolpaths from those guidepaths with a minimum number of starts and stops, a finite element subsystem that computes spatially varying material orthotropy from those toolpaths and then solves a boundary value problem to determine a figure of merit for the design, and an optimization subsystem that uses that figure of merit to update the mathematical description of the part orthotropy to iteratively develop an improved part. The optimization subsystem also includes convergence criteria to indicate when toolpaths have been achieved that yield a sufficiently optimal part has been achieved. The toolpath generate can then output the final toolpaths, which are converted to suitable code that controls the motion of the 3D printer toolhead and allows the optimized 3D part to be manufactured.

King, Michael J.↗

NASA NTRS2017

The Hazard of Volcanic Ash Ingestion

A research team of U.S. Government agencies and engine manufacturers conducted an experiment to test volcanic-ash ingestion by a NASA owned engine in the same family as the PW 2000 that was donated by the U.S. Air Force. The experiment, called Vehicle Integrated Propulsions Research (VIPR) test, was conducted under the auspices of NASAs Convergent Aeronautics Solutions (CAS) Program and took place in summer of 2015 at Edwards AFB in California as an on-ground, on-wing test. The primary objectives of the volcanic ash test were to determine the effect on the engine of several hours of exposure to low to moderate ash concentrations and to evaluate the capability of engine health management technologies for detecting these effects. The target concentrations of volcanic ash tested were at 1 and 10 mgm3. A natural volcanic ash was used that is representative of distal ash clouds many 100s to 1000 km from a volcanic source. The glassy ash particles were expected to soften and become less viscous when exposed to the high temperatures of the combustion chamber, then stick to the nozzle guide vanes of the high-pressure turbine and this was observed. Numerous observations and measurements of the engines performance and degradation were made during the course of the experiment, including borescope inspections after each test run. The engine has been disassembled so that detailed inspections of the engine effects have been made. A summary of the test methodology and execution will be made along with results from the test. While not intended to be sufficient for rigorous certification of engine performance when ash is ingested, the experiment should provide useful information to aircraft manufacturers, airline operators, and military and civil regulators in their efforts to evaluate the range of risks that ash hazards pose to aviation.

Lekki, John↗

DOE OSTI2024

Aligning lithium metal battery research and development across academia and industry

Successful integration of metallic lithium anodes into secondary batteries could enhance energy density and enable new forms of electrified transportation. However, the outlook for widespread lithium metal adoption in energy storage devices remains mixed. This comes in part from existing gaps in our understanding of the relationships connecting the initial state of lithium, its evolution with cycling, and end-of-life state. It remains important to develop standardized protocols for material and cell characterization, cycling performance, safety, and recycling procedures for lithium metal-based batteries. In February 2023 a cohort of scientists and engineers from academia, national laboratories, and industry gathered to converge on a list of critical challenges and action items to provide better understanding of lithium metal evolution and to enhance academic, governmental, and industrial partnerships to address these challenges. Here, we highlight the major discussion topics revolving around the manufacturing of lithium metal, its related metrology and integration into battery form factors, and best practices testing its electrochemical performance relevant to automotive applications. We introduce a power-controlled discharge testing protocol for research and development cells, in alignment between major automotive stakeholders, that may reveal lithium metal battery dynamics closer to practical driving behavior.

25 ENERGY STORAGE↗

DOE OSTI2022

Structures of drug-specific monoclonal antibodies bound to opioids and nicotine reveal a common mode of binding

Opioid-related fatal overdoses have reached epidemic proportions. Because existing treatments for opioid use disorders offer limited long-term protection, accelerating the development of newer approaches is critical. Monoclonal antibodies (mAbs) are an emerging treatment strategy that targets and sequesters selected opioids in the bloodstream, reducing drug distribution across the blood-brain barrier, thus preventing or reversing opioid toxicity. We previously identified a series of murine mAbs with high affinity and selectivity for oxycodone, morphine, fentanyl, and nicotine. To determine their binding mechanism, we used X-ray crystallography to solve the structures of mAbs bound to their respective targets, to 2.2 Å resolution or higher. Structural analysis showed a critical convergent hydrogen bonding mode that is dependent on a glutamic acid residue in the mAbs’ heavy chain and a tertiary amine of the ligand. Further, characterizing drug-mAb complexes represents a significant step toward rational antibody engineering and future manufacturing activities to support clinical evaluation.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

Ion Beam Figuring System for Synchrotron X-Ray Mirrors Achieving Sub-0.2-µrad and Sub-0.5-nm Root Mean Square

Abstract Optics with high-precision height and slope are increasingly desired in numerous industrial fields. For instance, Kirkpatrick–Baez (KB) mirrors play an important role in synchrotron X-ray applications. A KB system is composed of two aspherical, grazing-incidence mirrors used to focus an X-ray beam. The fabrication of KB mirrors is challenging due to the aspherical departure of the mirror surfaces from base geometries and the high-quality requirements for slope and height residuals. In this paper, we present the process of manufacturing an elliptical cylinder KB mirror using our in-house-developed ion beam figuring (IBF) and metrology technologies. First, the key aspects of figuring and finishing processes with IBF are illustrated in detail. The effect of positioning error on the convergence of the residual slope error is highlighted and compensated. Finally, inspection and cross-validation using different metrology instruments are performed and used as the final validation of the mirror. Results confirm that relative to the requested off-axis ellipse, the mirror has achieved 0.15-µrad root mean square (RMS) and 0.36-nm RMS residual slope and height errors, respectively, while maintaining the initial 0.3-nm RMS microroughness.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Transformational Challenge Reactor – On the Application of Design for Additive Manufacturing (DfAM) Techniques to the Conception of Nuclear Core

Additive manufacturing (AM) technologies are radically changing the way objects are designed and manufactured. They allow building by deposition and solidification of material layer by layer, enabling the possibility to create simple and complex features alike, almost seamlessly. Generally, the design optimization process requires to define objectives, design variables and constraints. Additive manufacturing does not challenge this process per se but does allow designers to completely redefine the constraints space as the ones originating from fabrication can be considerably relaxed compared to more “traditional” manufacturing. Thus, design optimization becomes naturally far more responsive to the actual physics being solved and considerably less influenced by fabrication limitations, leading to dramatically different designs. To take advantage of these new opportunities, so-called Designing for Additive Manufacturing (DfAM) techniques are emerging. Development of design techniques specifically tailored for additive manufacturing is warranted because, considering AM, the design space is typically considerably larger than with traditional manufacturing. The ability to explore the design space efficiently is of paramount importance for designers. This study proposes to investigate and apply some of these DfAM techniques to the conception of nuclear core. The goal being to assess if these new methods can be applied to core design and if core design could benefits from additive manufacturing technologies. After a brief investigation on the pertinence of some DfAM techniques for core design, algorithms are proposed and a workflow is established to carry neutronics and steady-state thermal-hydraulics analyses. To diminish the work load, the workflow has been automated using python modules. These modules allow the rapid creation of input files, post-treatment of output files and visualization. To test the pertinence of the proposed workflow, three test cases have been investigated: a research and test reactor, a micro-reactor and a space propulsion reactor. These test cases offered a variety of objectives, constraints and operating conditions. It is observed that the proposed workflow is capable of converging quickly and efficiently to valid design solutions. It is then concluded that DfAM techniques can be applied to core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Polyhydroxyalkanoates in emerging recycling technologies for a circular materials economy

Circular polymer systems, specifically polyesters operating through chemical and biological technologies, are approaching a critical moment of industrial adoption and scale-up feasibility. At the same time, polyhydroxyalkanoate (PHA) production, scale-up, and resulting material development is converging toward commodity applications. The current PHA end-of-life philosophy, however, focalizes leveraging inherent biodegradability to circumvent plastic waste accumulation. If indeed a substantial replacement of incumbent single-use plastics with PHA alternatives is to be met in commercial manufacture, we emphasize the importance of linking PHA development with feasible polymer recycling technologies. In other words, a PHA materials economy is significantly more carbon- and cost-favorable when efficient mechanical (reprocessing), chemical (deconstruction, depolymerization), or biological (enzymatic) recycling is prioritized over biodegradation or composting. In this perspective, we discuss strategies for PHA recyclable-by-design principles, guidable by developing machine learning tools, as well as material compatibility with closed-loop recycling technologies. Additionally, we posit compelling life-cycle assessment incentives for adopting polymer reclamation over competing pathways. Ultimately, we hope this narrative further inspires the alignment between PHA design with growing calls for a circular material economy.

36 MATERIALS SCIENCE↗

NASA NTRS2015

The Development of a Deflectometer for Accurate Surface Figure Metrology

Marshall Space Flight Center is developing the method of direct fabrication for high resolution full-shell x-ray optics. In this technique the x-ray optics axial profiles are figured and polished using a computer-controlled ZeekoIRP600X polishing machine. Based on the Chandra optics fabrication history about one third of the manufacturing time is spent on moving a mirror between fabrication and metrology sites, reinstallation and alignment with either the metrology or fabrication instruments. Also, the accuracy of the alignment significantly affects the ultimate accuracy of the resulting mirrors. In order to achieve higher convergence rate it is highly desirable to have a metrology technique capable of in situ surface figure measurements of the optics under fabrication, so the overall fabrication costs would be greatly reduced while removing the surface errors due to the re-alignment necessary after each metrology cycle during the fabrication. The goal of this feasibility study is to demonstrate if the Phase Measuring Deflectometry can be applied for in situ metrology of full shell x-ray optics. Examples of the full-shell mirror substrates suitable for the direct fabrication

X-ray optics metrology↗

DOE OSTI2021

A deterministic verification strategy for electrostatic particle-in-cell algorithms in arbitrary spatial dimensions using the method of manufactured solutions

As simulations of kinetic plasmas continue to increase in scope and complexity, a rigorous and straightforward method for verifying particle-in-cell (PIC) implementations is necessary to ensure their correctness. Here, in this paper, we present a deterministic method for the rigorous verification of multidimensional, multispecies, electrostatic particle-in-cell codes based on the method of manufactured solutions. Specifically, we prove that rigorous verification is possible through the exclusive examination of errors of grid quantities (i.e., moments and/or fields), allowing for a very light-weight and non-intrusive implementation in existing PIC codes. This is a marked improvement over earlier PIC verification approaches (only demonstrated with one species in 1D-1V), which rely on the comparison of cumulative distribution functions, and are invasive on the code base, introduce additional stochastic noise, are significantly more computationally expensive, and lack rigorous convergence properties. Interestingly, we show that different grid quantities feature different rates of convergence with the number of particles and mesh size, impacting the verification process. These theoretical results are confirmed numerically with a multi-species 2D-2V particle-in-cell code, including the ability of the method to detect order reduction due to an incorrect implementation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Validating the Use of Gaussian Process Regression for Adaptive Mapping of Residual Stress Fields

Probing the stress state using a high density of measurement points is time intensive and presents a limitation for what is experimentally feasible. Alternatively, individual strain fields used for determining stresses can be reconstructed from a subset of points using a Gaussian process regression (GPR). Results presented in this paper evidence that determining stresses from reconstructed strain fields is a viable approach for reducing the number of measurements needed to fully sample a component’s stress state. The approach was demonstrated by reconstructing the stress fields in wire-arc additively manufactured walls fabricated using either a mild steel or low-temperature transition feedstock. Effects of errors in individual GP reconstructed strain maps and how these errors propagate to the final stress maps were assessed. Implications of the initial sampling approach and how localized strains affect convergence are explored to give guidance on how best to implement a dynamic sampling experiment.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Mirror-centered representation of a focusing hyperbolic mirror for X-ray beamlines

Conic sections are commonly used in reflective X-ray optics. Hyperbolic mirrors can focus a converging light source and are frequently paired with elliptical or parabolic mirrors in Wolter type configurations. This paper derives the closed-form expression for a mirror-centered hyperbolic shape, with zero-slope at the origin. Combined with the slope and curvature, such an expression facilitates metrology, manufacturing and mirror-bending calculations. Previous works consider ellipses, parabolas, magnifying hyperbolas or employ lengthy approximations. Here, the exact shape function is given in terms of the mirror incidence angle and the source and image distances.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Rapid Tuning of Synchrotron Surrogate Model at the Recycler Ring

The 8 GeV proton-storage Recycler Ring (RR) is essential for reaching megawatt beam intensity goals for the DUNE neutrino beam at Fermilab. Custom shims on each RR permanent magnet were designed to cancel manufacturing defects and bring magnetic fields to the design values. Remaining imperfections cause the observed tune variation vs energy to deviate from what is calculated using the design fields. Using the POUNDERS (“Practical Optimization Using No Derivatives for sums of Squares”) optimization method with Synergia in the loop, we demonstrate rapid convergence to a set of additive, higher-order multipole moments of these magnetic shims which reproduce that observed variation, and show that the convergence advantage grows with the parameter-space dimensionality.

43 PARTICLE ACCELERATORS↗