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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 NTRS1988

Design of a sample acquistion system for the Mars exobiological penetrator

The Mars Exobiological Penetrator will be imbedded into several locations on the Martian surface. It contains various scientific instruments, such as an Alpha-Particle Instrument (API), Differential Scanning Calorimeter (DSC), Evolved Gas Analyzer (EGA) and accelerometers. A sample is required for analysis in the API and DSC. To avoid impact contaminated material, this sample must be taken from soil greater than 2 cm away from the penetrator shell. This study examines the design of a dedicated sampling system including deployment, suspension, fore/after body coupling, sample gathering and placement. To prevent subsurface material from entering the penetrator sampling compartment during impact, a plug is placed in the exit hole of the wall. A U-lever device is used to hold this plug in the penetrator wall. The U-lever rotates upon initial motion of the core-grinder mechanism (CGM), releasing the plug. Research points to a combination of coring and grinding as a plausible solution to the problem of dry drilling. The CGM, driven by two compressed springs, will be deployed along a tracking system. A slowly varying load i.e., springs, is favored over a fixed displacement motion because of its adaptability to different material hardness. However, to accommodate sampling in a low density soil, two dash pots set a maximum transverse velocity. In addition, minimal power use is achieved by unidirectional motion of the CGM. The sample will be transported to the scientific instruments by means of a sample placement tray that is driven by a compressed spring to avoid unnecessary power usage. This paper also explores possible modifications for size, weight, and time as well as possible future studies.

Thomson, Ron↗

NASA NTRS2012

Methods and apparatus for coating particulate material

Methods and apparatus for coating particulate material are provided. The apparatus includes a vessel having a top and a bottom, a vertically extending conduit having an inlet in the vessel and an outlet outside of the vessel, a first fluid inlet in the bottom of the vessel for introducing a transfer fluid, a second fluid inlet in the bottom of the vessel for introducing a coating fluid, and a fluid outlet from the vessel. The method includes steps of agitating a material, contacting the material with a coating material, and drying the coating material to produce a coated material. The invention may be adapted to coat aerogel beads, among other materials. A coated aerogel bead and an aerogel-based insulation material are also disclosed.

Littman, Howard↗

NASA NTRS2013

Methods for Coating Particulate Material

Littman, Howard↗

NASA NTRS2014

Coated Aerogel Beads

Littman, Howard↗

DOE OSTI2025

A comparison of surrogate constitutive models for viscoplastic creep simulation of HT-9 steel

Mechanistic microstructure-informed constitutive models for the mechanical response of polycrystals are a cornerstone of computational materials science. However, as these models become increasingly more complex – often involving coupled differential equations describing the effect of specific deformation modes – their associated computational costs can become prohibitive, particularly in optimization or uncertainty quantification tasks that require numerous model evaluations. To address this challenge, surrogate constitutive models that balance accuracy and computational efficiency are highly desirable. Data-driven surrogate models, that learn the constitutive relation directly from data, have emerged as a promising solution. In this work, we develop two local surrogate models for the viscoplastic response of a steel: a piecewise response surface method and a mixture of experts model. These surrogates are designed to adapt to complex material behavior, which may vary with material parameters or operating conditions. The surrogate constitutive models are applied to creep simulations of HT-9 steel, an alloy of considerable interest to the nuclear energy sector due to its high tolerance to radiation damage, using training data generated from viscoplastic self-consistent (VPSC) simulations. In conclusion, we define a set of test metrics to numerically assess the accuracy of our surrogate models for predicting viscoplastic material behavior, and show that the mixture of experts model outperforms the piecewise response surface method in terms of accuracy.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Application of Weak-Beam Dark-Field STEM for Dislocation Loop Analysis

Nanoscale dislocation loops formed by irradiation can significantly contribute to both irradiation hardening and embrittlement of materials when subjected to extreme nuclear reactor environments. Here, this study explores the application of weak-beam dark-field (WBDF) scanning transmission electron microscopy (STEM) methods for quantitative irradiation-induced defect analysis in crystalline materials, with a specific focus on dislocation loop imaging and analysis. A high-purity Fe-5 wt% Cr model alloy was irradiated with 8 MeV Fe 2+ ions at 450°C to a fluence of 8.8 × 10 19 m -2 , inducing dislocation loops for analysis. While transmission electron microscopy (TEM) has traditionally been the primary tool for dislocation imaging, recent advancements in STEM technology have reignited interest in using STEM for defect imaging. This study introduces and compares three WBDF STEM methods, demonstrating their effectiveness in suppressing background contrasts, isolating defect information for dislocation loop type classification, providing finer dislocation line images for small loop analysis, and presenting inside–outside contrast for identifying loop nature. Experimental findings indicate that WBDF STEM methods surpass traditional TEM approaches, yielding clearer and more detailed images of dislocation loops. The study concludes by discussing the potential applications of WBDF STEM techniques in defect analysis, emphasizing their adaptability across various material systems beyond nuclear materials.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Deep-learning based artificial intelligence tool for melt pools and defect segmentation

Accelerating fabrication of additively manufactured components with precise microstructures is important for quality and qualification of built parts, as well as for a fundamental understanding of process improvement. Accomplishing this requires fast and robust characterization of melt pool geometries and structural defects in images. This paper proposes a pragmatic approach based on implementation of deep learning models and self-consistent workflow that enable systematic segmentation of defects and melt pools in optical images. Deep learning is based on an image-to-image translation–conditional generative adversarial neural network architecture. An artificial intelligence (AI) tool based on this deep learning model enables fast and incrementally more accurate predictions of the prevalent geometric features, including melt pool boundaries and printing-induced structural defects. We present statistical analysis of geometric features that is enabled by the AI tool, showing strong spatial correlation of defects and the melt pool boundaries. The correlations of widths and heights of melt pools with dataset processing parameters show the highest sensitivity to thermal influences resulting from laser passes in adjacent and subsequent layer passes. The presented models and tools are demonstrated on the aluminum alloy and datasets produced with different sets of processing parameters. However, they have universal quality and could easily be adapted to different material compositions. The method can be easily generalized to microstructural characterizations other than optical microscopy.

additive manufacturing↗

DOE OSTI2025

Field-Driven Out-of-Equilibrium Collective Patterns for Swarm Micro-Robotics

Soft robotics has been rapidly advancing, offering significant improvements over traditional rigid robotic systems through the use of compliant materials that enhance adaptability and interaction with the environment. However, current approaches face critical challenges, including the reliance on complex “top-down” fabrication techniques and the difficulty of wireless powering and control at the microscale. Swarm robotics introduces a paradigm shift, leveraging collective dynamics to achieve cooperative and adaptable behaviors among multiple robotic units. Inspired by nature, this “bottom-up” approach enables swarm robots to execute task-specific reconfigurations, enhancing flexibility and robustness. Field-driven active colloids emerge as a promising platform for swarm microrobotics, capable of self-propulsion and self-organization into dynamic collective patterns under external field excitation and manipulation. These systems mimic biologically inspired swarm behaviors, such as flocking and vortex formation, providing a versatile foundation for designing innovative swarm microrobots. Here, this review discusses the principles of electric and magnetic field-driven collective self-organization, focusing on the particle dynamics, the emergence of collective swarm patterns, and illustrative examples of functional swarm microrobots. It concludes with future perspectives on harnessing these systems for adaptive, scalable, and multifunctional microrobotic applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2024

Training physical matter to matter

A new paradigm for generating adaptive functionality in materials.

Chemistry↗

NASA NTRS1979

Ambient curing fire resistant foams

The feasibility of development of an ambient curing foam is described. The thermal stability and flame spread index of the foams were found to be comparable to those of the high-temperature cured polyimide foams by Monsanto two-foot tunnel test and NASA T-3 Fire test. Adaptation of the material to spray in place applications is described

Hamermesh, C. L.↗

NASA NTRS1983

Robotic Water Blast Cleaner

Water blasting system under development removes hard, dense, extraneous material from surfaces. High pressure pump forces water at supersonic speed through nozzle manipulated by robot. Impact of water blasts away unwanted material from workpiece rotated on air bearing turntable. Designed for removing thermal-protection material, system is adaptable to such industrial processes as cleaning iron or steel castings.

Sharpe, M. H.↗

NASA NTRS1987

Progress on thin-film sensors for space propulsion technology

The objective is to develop thin-film thermocouples for Space Shuttle Main Engine (SSME) components. Thin-film thermocouples have been developed for aircraft gas turbine engines and are in use for temperature measurement on turbine blades to 1800 F. The technology established for aircraft gas turbine engines will be adapted to the materials and environment encountered in the SSME. Specific goals are to expand the existing in-house thin-film sensor technology and to test the survivability and durability of thin-film sensors in the SSME environment.

Kim, Walter S.↗

NASA NTRS1989

A tough performance simultaneous semi-interpenetrating polymer network

A semi-interpenetrating polyimide (semi-IPN) network and methods for making and using the same are disclosed. The semi-IPN system comprises a high performance thermosetting polyimide having an acetylene-terminated group acting as a crosslinking site and a high performance linear thermoplastic polyimide. The polymer is made by combining low viscosity precursors and low molecular weight polymers of the thermosetting and thermoplastic polyimides and allowing them to react in the immediate presence of each other to form a simultaneous semi-interpenetrating polyimide network. Provided is a high temperature system having significantly improved processability and damage tolerance while maintaining excellent thermo-oxidative stability, mechanical properties and resistance to humidity, when compared with the commercial high temperature resin, Thermid 600. This material is particularly adapted for use as a molding, adhesive and advanced composite matrix for aerospace structural and electronic applications.

Pater, Ruth H.↗

NASA NTRS1994

Characterization of Metal Matrix Composites

Experimental methods were developed, adapted, and applied to the characterization of a metal matrix composite system, namely, silicon carbide/aluminim (SCS-2/6061 Al), and its constituents. The silicon carbide fiber was characterized by determining its modulus, strength, and coefficient of thermal expansion. The aluminum matrix was characterized thermomechanically up to 399 C (750 F) at two strain rates. The unidirectional SiC/Al composite was characterized mechanically under longitudinal, transverse, and in-plane shear loading up to 399 C (750 F). Isothermal and non-isothermal creep behavior was also measured. The applicability of a proposed set of multifactor thermoviscoplastic nonlinear constitutive relations and a computer code was investigated. Agreement between predictions and experimental results was shown in a few cases. The elastoplastic thermomechanical behavior of the composite was also described by a number of new analytical models developed or adapted for the material system studied. These models include the rule of mixtures, composite cylinder model with various thermoelastoplastic analyses and a model based on average field theory. In most cases satisfactory agreement was demonstrated between analytical predictions and experimental results for the cases of stress-strain behavior and thermal deformation behavior at different temperatures. In addition, some models yielded detailed three-dimensional stress distributions in the constituents within the composite.

Daniel, I. M.↗

NASA NTRS1995

Multivariate Quantitative Chemical Analysis

Technique of multivariate quantitative chemical analysis devised for use in determining relative proportions of two components mixed and sprayed together onto object to form thermally insulating foam. Potentially adaptable to other materials, especially in process-monitoring applications in which necessary to know and control critical properties of products via quantitative chemical analyses of products. In addition to chemical composition, also used to determine such physical properties as densities and strengths.

Kinchen, David G.↗

NASA NTRS2001

Comparison of Angle of Attack Measurements for Wind Tunnel Testing

Two optical systems capable of measuring model attitude and deformation were compared to inertial devices employed to acquire wind tunnel model angle of attack measurements during the sting mounted full span 30% geometric scale flexible configuration of the Northrop Grumman Unmanned Combat Air Vehicle (UCAV) installed in the NASA Langley Transonic Dynamics Tunnel (TDT). The overall purpose of the test at TDT was to evaluate smart materials and structures adaptive wing technology. The optical techniques that were compared to inertial devices employed to measure angle of attack for this test were: (1) an Optotrak (registered) system, an optical system consisting of two sensors, each containing a pair of orthogonally oriented linear arrays to compute spatial positions of a set of active markers; and (2) Video Model Deformation (VMD) system, providing a single view of passive targets using a constrained photogrammetric solution whose primary function was to measure wing and control surface deformations. The Optotrak system was installed for this test for the first time at TDT in order to assess the usefulness of the system for future static and dynamic deformation measurements.

Jones, Thomas, W.↗

NASA NTRS2018

New Levels of High Angular Resolution EBSD Performance via Inverse Compositional Gauss-Newton Digital Image Correlation

Conventional high angular resolution electron backscatter diffraction (HREBSD) uses cross-correlation to track features between diffraction patterns, which are then related to the relative elastic strain and misorientation between the diffracting volumes of material. This paper adapts inverse compositional Gauss Newton (ICGN) digital image correlation (DIC) to be compatible with HREBSD. ICGN works by efficiently tracking not just the shift in features, but also the change in their shape. Modeling a shape change as well as a shift results in greater accuracy. This method, ICGN HREBSD, is applied to a simulated data set, and its performance is compared to conventional cross-correlation HREBSD, and cross-correlation HREBSD with remapping. ICGN HREBSD is shown to have about half the strain error of the best cross-correlation method with a comparable computation time.

T. J. Ruggles↗

NASA NTRSDate not supplied

Leading University Students to the Edge of Space

For over 16 years, the Louisiana Space Grant Consortium (LaSPACE), the NASA Balloon Program Office (BPO), and the NASA Columbia Scientific Balloon Facility (CSBF) have collaborated in a series of high altitude balloon-based programs involving hands-on authentic learning experiences that expose university students and other participants to technical skills, teamwork dynamics, and effective communication methods. Such programs go beyond what is possible to achieve in a normal classroom and help prepare future engineers and scientists for a successful aerospace workforce career. In our collaborative effort, LaSPACE has focused on the program content and student mentoring while NASA BPO and CSBF provide balloon flight support and operations. The entry-level Louisiana Aerospace Catalyst Experiences for Students (LaACES) builds students’ skills in basic electronics, sensor interfacing, real-time programming, mechanical development, and project management. These skills are then applied to the design, development, fabrication, and flight of a small (∼500 gram) balloon payload. Finally, the payloads are flight-tested to an altitude of ∼30 km using a 2 kg latex sounding balloon. The LaACES program includes a set of lectures, activities, and Arduino Mega based electronic kits that are used for skill building and as a core control system for the student payload. The more advanced High Altitude Student Platform (HASP) is designed to carry ∼twelve 3 to 20 kg student payloads to an altitude of about 36 kilometers with flight durations of 10 to 20 hours using a ∼311,500 cubic meter, zero pressure balloon. HASP provides all student payloads with power, downlink telemetry, uplink commanding, and real-time HD video for instrument control and assessment during the flight. While originally developed for university students, these programs have been adapted to projects focused on high school teachers as well as affecting minorities underrepresented in aerospace related science and engineering fields. We are now in the process of adapting the LaACES materials to a pre-engineering curriculum for high school students as well as for widespread access over the internet. During this presentation, we will provide details of both the LaACES and HASP programs, how these programs have engaged participants from all demographic groups, and our current plans for continuing and expanding upon our success.

University↗