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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

RapidClave® Technology Demonstrations – II Hat Stiffener

This project sought to evaluate the cost and performance of both polymeric and metallic tooling for use with the RapidClave® composite process. Teijin’s rapid cure carbon/epoxy prepreg, Q183, was selected to fabricate demonstration components, of aerospace design, which currently are fabricated via compression molding using matched steel tooling. The ability to fabricate components using this prepreg in the RapidClave®, and using low cost single sided tooling, could significantly reduce the cost of part manufacture and shorten production lead times for tooling fabrication. The component demonstration article was a “hat stiffener” geometry typically used to reinforce fuselage or wing skins of an aircraft. A rapid preforming process was demonstrated and rapid process cycle times similar to compression molding were achieved by placing the preform on hot tooling, thus avoiding the time and energy associated with typical thermal cycling. A 90% reduction in tooling cost was achieved through the use of single sided aluminum or polymeric additive tooling when compared to compression molding matched steel tooling. In addition to rapid cycle times, RapidClave® offers the ability to change out tooling in minutes such that multiple part geometries can be fabricated in one shift.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessing the Vulnerability of Unmanned Aircraft Systems to Directed Acoustic Energy

The increasingly large payloads of Unmanned Aircraft Systems (UASs) are exponentially increasing the threat to the nuclear enterprise. Current mitigation using RF interference is effective, but not feasible for fully autonomous systems and is prohibited in many areas. A new approach to UAS threat mitigation is needed that does not create radio interference but is effective against any type of vehicle. At the present time there is no commercial counter-UAS system that directly assaults the mems gyros and accelerometers in the Inertial Measurement Unit on the aircraft. But lab testing has revealed resonances in some IMUs that make them susceptible to moderate amplitude acoustic monotones. Sandia's energetic materials facility has enabled a quick and thorough exploration of UAS vulnerability to directed acoustic energy by using intense acoustic impulses to destabilize or down a UAS. We have: 1) detonated/deflagrated explosive charges of various sizes; 2) accurately measured impulse pressure and pulse duration; 3) determined what magnitude of acoustic insult to the IMU disrupts flight and for how long and; 4) determined if the air blast/shock wave on aircraft/propellers disrupts flight.

42 ENGINEERING↗
DOE OSTI2024

Prediction of regional infrasound produced by supersonic sources using a ray-based Mach cone source

The geometry of the Mach cone produced by a supersonic source is analyzed and mapped into initial conditions used in acoustic ray tracing. The resulting source model is combined with spherical geometry ray tracing methods to enable propagation simulations for infrasonic signals produced by bolides, space debris, rockets, aircraft, and other fast-than-sound sources out to typical infrasonic observation distances of hundreds or thousands of kilometers. Idealized linear and parabolic trajectories typical of bolides and rockets, respectively, are used to demonstrate the calculation of regional infrasonic signals produced by such sources and characteristics of the radiated infrasonic waves are found to vary strongly with the geometry of the trajectory and atmospheric structure. Predicted regional infrasonic signals are compared with those observed from a November 2020 bolide that passed over Scandinavia using a combination of institutionally maintained infrasound stations and “citizen scientist” data from the Raspberry Shake data repository.

42 ENGINEERING↗
DOE OSTI2024

Data Based Shock Test Specification

It is vital that avionic packages used for testing and certifying the reliability and safety of U.S. nuclear weapons with platform aircraft survive exposure to shock environments during transportation and delivery. The objective of this research was to characterize the response to these transportation shock environments delivering accurate shock test specifications in order to set laboratory programming material and device certification rigor. Responses to shock events were analyzed in the frequency domain via the Shock Response Spectrum (SRS). Shocks were then grouped based on respective behavior of maximum response accelerations which were pseudorandomly resampled and compared to test data to form test specifications based on the MinerPalmgren hypothesis. In addition to discovering significant over testing in current shock specifications, a new systematic, data-driven approach to designing shock specifications was formulated.

42 ENGINEERING↗
DOE OSTI2022

Adaptive Sampling for In Situ Cloud Probe (Final Report)

Clouds play a leading role in the Earth's global energy and solar radiation balance and hydrological cycle. Improving cloud models requires detailed information on the cloud microphysical properties, such as droplet size distribution and number density, liquid water content and cloud composition (droplets, ice particles), which can only be provided by aerial in situ measurements. However, for many atmospheric measurement instruments, the lack of flexibility in selecting the operational mode during operation can lead to uncertainties in sampling and measurement characteristics under continuously varying atmospheric conditions. This SBIR project is developing an advanced, compact optical imaging technology for in situ characterization of cloud hydrometeors. The development involves a deep modification of the existing Mesa Photonics’ Cloud Droplet Measurement System (CDMS) in order to implement real-time automatic adaptive sampling based on the acquired in situ data and environmental parameters. The new system, CDMS-2, implements two measurement modes: side-scatter imaging for smaller hydrometeors and direct bright-field-illumination imaging for larger hydrometeors in a significantly larger sample volume. The system measures the droplet size distribution (DSD) and number density with an added capability of discriminating between liquid water and ice hydrometeors (based on polarization-resolved side-scatter imaging). The instrument will implement automatic switching or alternating between the regular side-scatter imaging mode and sparse/large hydrometeor mode (based on the acquired data). Other adaptive sampling capabilities include variable sample volume and dynamic range (based on the measured DSD). The preferred deployment platforms are uncrewed aircraft systems (UAS) and tethered balloon/kite systems (TBS). The Phase I project achieved (or exceeded) the goals listed in the Work Plan. A CDMS-2 laboratory prototype implementing the polarization-resolved side-scatter imaging mode and direct bright-field-illumination imaging mode was designed and built. Additional capabilities included the variable illumination pulse energy and sample volume. The smallest detectable droplet diameter was improved to 3–4 μm (from the nominal 10 μm value specified for the original CDMS). Discrimination between water droplets and ice particles was experimentally demonstrated. The Phase I prototype was extensively tested and calibrated in the laboratory and also tested in the Pi Cloud Chamber at Michigan Technological University (MTU). The two intensive experimental campaigns at MTU provided unique opportunities of testing the CDMS-2 laboratory prototype under realistic warm and mixed-phase cloud conditions (stable for long periods of time), testing different sampling modes and intercomparing the CDMS-2 prototype to other co-located cloud characterization instruments. The Phase I project successfully demonstrated the feasibility of the proposed technology and identified the engineering challenges of designing a field deployable prototype instrument in Phase II. The Phase I study provides a solid basis for development, characterization and field-testing of the proposed advanced cloud probe with adaptive sampling in Phase II followed by commercialization of the technology in Phase III.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Drone Fleet Summary: NNLEMS UxS Rolodex entry for Sandia

Sandia’s UAS Aviation Operations Unit (UAOU) was established in 2019 to be the single entity at Sandia conducting UAS Ops in support the labs Uncrewed Aircraft Systems (UAS) activities. The UAOU currently consists of >330 FAA Registered UAS with a large variety of primarily Class 1&2 UAS: fixed wing (>90), multi-rotor (>230), hybrids, VTOLs, jets, and balloons. Many of these are threat vehicles presented as targets to Counter-UAS (CUAS) systems as part of performance tests, with the remainder in support of other projects across Sandia often with custom payload needs. The UAOU has ~15 primary pilots and reach back to another ~45 FAA Certified Remote Pilots across Sandia. The team conducts flight and CUAS operations at many test locations, including OCONUS. Sandia was awarded the 2024 DOE Federal Aviation Safety Program Award.

42 ENGINEERING↗
DOE OSTI2026

Event-Driven 3D Sensing Architecture

Some events happen too quickly to capture twice. Whether tracking satellites, monitoring aircraft, observing autonomous systems, or recording high speed industrial processes, imaging systems often have only one opportunity to collect the right information. If a camera is focused on the wrong distance, uses the wrong exposure, or cannot keep pace with rapid motion, important details may be lost forever. Los Alamos National Laboratory has developed an event-driven imaging architecture that preserves more information during data collection than a conventional camera. Instead of committing to a single image, the system captures data that can later be used to digitally adjust focus and exposure while reconstructing the scene in three dimensions. The result is a more flexible approach for imaging dynamic environments where conventional cameras can struggle.

42 ENGINEERING↗
DOE OSTI2025

Flux-Switching Machine Based All-Electric Power Train for Future Aircraft

This research investigates a flux-switching motor with superconducting and cryogenically cooled windings, aimed at achieving exceptionally high power densities. In addition to the motor’s topology and superconducting windings, it was found that power density could be further enhanced by incorporating superconducting shields on the rotor at the interpole locations. The resulting publications and patented technology outline the design process. A motor power density of 64 kW/kg—including housing materials—was achieved for a 1 MW design, surpassing the performance of existing motors. An electronic drive was also developed, achieving a power density of 47 kW/kg. This includes the mechanical structure of the drivetrain, for which a detailed CAD model was created, resulting in an overall drivetrain power density of 27 kW/kg.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Cooling Strategies for an Electric Motor with Additively Manufactured Hollow Conductors and Distributed Power Electronics Integrated with Heat Pipes

This paper discusses design tradeoffs and thermal modeling explored in cooling strategies for an aircraft propulsion electric motor with additively manufactured coils and distributed power electronics integrated with heat pipes. Design tradeoffs include heat pipe Qmax performance related to inclination, condenser configuration, coolant type, coolant flow path complexity, and ease of access to modular power electronics. Three cooling strategies were selected and realized into CAD models. These models were further evaluated using 3D thermal FEA and optimization tools to explore cooling geometry details that include fin thickness, spacing and count with the objective to minimize fin mass under a set of constraints. Lastly, motorette test data is presented comparing air versus liquid cooling of heat pipes.

additive manufacturing↗
DOE OSTI2022

Nondestructive Evaluation (NDE) of Cable Anomalies using Frequency Domain Reflectometry (FDR) and Spread Spectrum Time Domain Reflectometry (SSTDR)

This report presents a comparative assessment of the performance of frequency domain reflectometry (FDR) and spread spectrum time domain reflectometry (SSTDR) in detecting a wide range of electrical cable anomalies. All tests and results reported herein were performed at the PNNL Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed. The primary objective of this work was to evaluate the effectiveness of SSTDR, a fledgling cable monitoring technique that shows promise for application in online monitoring of energized cable systems, against FDR, an offline technique widely employed in the nuclear power plant (NPP) industry. FDR tests are becoming more widely used in nuclear power plant cable aging management and test programs – particularly for low voltage cables. FDR capabilities for these kinds of tests have been reported by PNNL and others. The FDR test is performed on de-energized cables by connecting the FDR instrument to two of the cable conductors, or one conductor and the shield. A broad band low voltage (< 5 V) chirp is introduced in the cable, and any reflected response is captured in the frequency domain. The captured reflection is then processed by performing an inverse Fourier transform to a time domain response which can then be converted to a distance response based on the cable velocity of propagation (VoP). SSTDR measurements are functionally similar to FDR measurements in that a broad-band voltage signal composed of a square or sine wave modulated pseudo-random sequence of chips (< 5 volts), is injected onto one of the cable conductors. The injected signal will experience partial energy reflection and transmission at each impedance discontinuity along the transmission line. Any reflected response is detected by computing a cross-correlation between the reflected signals and a delayed copy of the incident SSTDR signal. the time delay for the reflected signal to experience the best matched correlation with the incident signal, indicates the travel time for the signal to reach a change in impedance. By knowing this time delay and velocity of propagation (VoP) of the signal, one can compute the physical distance. A big advantage that SSTDR measurements have over other methods is the ability to be connected to energized or live wires (currently up to 1kV) thereby enabling online monitoring of cables. SSTDR has been used successfully in several applications, e.g., aircraft, rail, and photovoltaic systems. In this work FDR and SSTDR cable assessment techniques were used to characterize a variety of cable anomalies and faults including: (1) Presence or absence of a motor; (2) Ground faults and short circuit faults; (3) Moist environments and water ingress faults; (4) Accelerated thermal aging. Both shielded and non-shielded cables were evaluated in this report. Offline measurements were made using FDR and online measurements were made by SSTDR for a range of test scenarios. Based on the results across all cable anomalies evaluated in this study, FDR displayed high sensitivity towards cable condition assessment, while SSTDR showed promise for future application in monitoring NPP cable systems. However, further developments are suggested to improve the resolution and sensitivity of SSTDR towards faults and anomalies in low voltage cables.rt presents a comparative

42 ENGINEERING↗
DOE OSTI2023

Exploring the Performance Boundaries of a Small Reconfigurable Multi-Mission UAV through Multidisciplinary Analysis

The performance of a small reconfigurable unmanned aerial vehicle (UAV) is evaluated, combining a multidisciplinary approach in the computational analysis of additive manufactured structures, fluid dynamics, and experiments. Reconfigurable UAVs promise cost savings and efficiency, without sacrificing performance, while demonstrating versatility to fulfill different mission profiles. The use of computational fluid dynamics (CFD) in UAV design produces higher accuracy aerodynamic data, which is particularly important for complex aircraft concepts such as blended wing bodies. To address challenges relating to anisotropic materials, the Tsai–Wu failure criterion is applied to the structural analysis, using CFD solutions as load inputs. Aerodynamic performance results show the low-speed variant attains an endurance of 1 h, 48 min, whereas its high-speed counterpart is 29 min at a 66.7% higher cruise speed. Each variant serves different aspects of small UAS deployment, with low speed envisioned for high-endurance surveying, and high speed for long-range or time-critical missions such as delivery. The experimental and simulation results suggest room for design iteration, in wing area and geometry adjustments. Structural simulations demonstrated the need for airframe improvements to the low-speed configuration. This paper highlights the potential of reconfigurable UAVs to be useful across multiple industries, advocating for further research and design improvements.

42 ENGINEERING↗
DOE OSTI2024

Abrasive Waterjet Machining

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗
DOE OSTI2022

AviSense: A Real-time System for Detection, Classification, and Analysis of Aviation Signals

Wireless systems are an integral part of aviation. Apart from their apparent use in air-to-ground communication, wireless systems play a crucial role in avionic functions including navigation and landing. An interference-free wireless environment is therefore critical for the uninterrupted operation and safety of an aircraft. Hence, there is an urgency for airport facilities to acquire the capability to continuously monitor aviation frequency bands for real-time detection of interference and anomalies. To meet this critical need, we design and build AviSense, an SDR-based real-time, versatile system for monitoring aviation bands. AviSense detects and characterizes signal activities to enable practical and effective anomaly detection. We identify and tackle the challenges posed by a diverse set of critical aviation bands and technologies. We evaluate our methodology with real-world aviation signal measurements and two custom datasets of anomalous signals. We find that our signal classification capability achieves a true positive rate of ~99%, with few exceptions, and a false positive rate of less than 4%. We also demonstrate that AviSense can effectively distinguish between different types of anomalies. We build and evaluate a prototype implementation of AviSense that supports distributed monitoring.

42 ENGINEERING↗
DOE OSTI2021

Acquisition and Processing Considerations for Infrared Images of Rotating Turbine Blades

Abstract As designers aim to increase efficiency in gas turbines for aircraft propulsion and power generation, spatially resolved experimental measurements are needed to validate computational models and compare improvement gains of new cooling designs. Infrared (IR) thermography is one such method for obtaining spatially resolved temperature measurements. As technological advances in thermal detectors enable faster integration times, surface temperature measurements of rotating turbine blades become possible to capture including the smallest features. This paper outlines opportunities enabled by the latest IR detector technologies for capturing spatially resolved rotating blade temperatures, while also addressing some of the challenges of implementing IR for turbine rigs such as the one in the Steady Thermal Aero Research Turbine (START) Laboratory. This paper documents critical steps in achieving accurate measurements including calibration, integration times, spatial noise, and motion blur. From these results, recommendations are provided for achieving accurate IR measurements collected in a rotating turbine facility to study film cooling.

Engineering↗
DOE OSTI2020

Aerodynamic Data Fusion Toward the Digital Twin Paradigm

This paper considers the fusion of two aerodynamic data sets originating from differing types of physical or computer experiments. This paper specifically addresses the fusion of 1) noisy and in-complete fields from wind-tunnel measurements and 2) deterministic but biased fields from numerical simulations. These two data sources are fused in order to estimate the true field that best matches measured quantities that serve as the ground truth. For example, two sources of pressure fields about an aircraft are fused based on measured forces and moments from a wind-tunnel experiment. A fundamental challenge in this problem is that the true field is unknown and cannot be estimated with 100% certainty. A Bayesian framework is employed to infer the true fields conditioned on measured quantities of interest; essentially a statistical correction to the data is performed. The fused data may then be used to construct more accurate surrogate models suitable for early stages of aerospace design. An extension of the proper orthogonal decomposition with constraints is also introduced to solve the same problem. In this work, both methods are demonstrated on fusing the pressure distributions for flow past the RAE2822 airfoil and the Common Research Model wing at transonic conditions. Comparison of both methods reveals that the Bayesian method is more robust when data are scarce and capable of also accounting for uncertainties in the data. Furthermore, given adequate data, the proper-orthogonal-decomposition-based and Bayesian approaches lead to surprisingly similar results.

42 ENGINEERING↗
DOE OSTI2021

WSF PISA example for SAFER pilot

On October 15, 2021, the Radioactive and Hazardous Waste Management Facility Manager declared a Potential Inadequacy in the Safety Analysis (PISA) due to a new information relating to an error discovered in calculation AB-WSF-20-002. Calculation AB-WSF-20-002 is used to determine source terms and heat release rates for vehicle and aircraft impacts with fuel fires involving TRU waste containers. The source term for an aircraft’s impact has different source terms factors (i.e., DR, ARF, RF, LPF) that are applied to multiple categories of drums impacted in the accident scenario based on the physical stresses of the aircraft impact and involvement in the subsequent fuel pool fire. The source terms of the multiple categories of affected drums are summed to determine the final source term for the accident scenario. Certain categories of affected drums are modeled to lose their lid, causing material to eject and burn unconfined on the ground. For these specific categories, a lower ARF value was incorrectly applied in AB-WSF-20-002 (i.e., an ARF value of 1E-3 was used instead of the DOE-STD-5506-2007 directed ARF value of 1E-2). For these categories, the ARF is applied to a relatively small number of low-activity drums (i.e., 17 drums at 2.9 PE-Ci each) compared to the total number of drums affected (i.e., 166 drums totaling 621.8 PE-Ci). Therefore, this error is not expected to significantly increase final dose for the accident scenario. No immediate actions or compensatory measures are required to maintain the facility in a safe condition.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Using Hardware-In-The-Loop Methodology to Develop Test Systems

Hardware in the Loop (HIL) testing methodologies have become widespread in industry. Typically, they focus on developing control algorithms for systems such as autonomous vehicles or aircraft. An oft overlooked aspect of product development is the design and fabrication of a test system for validating that the product meets requirements. Abstractly, a test system differs little from a control system—testers provide signals to the unit, monitor feedback, and base decisions on the results. While the time scales may differ, the functionalities are conceptually similar. Viewed in this light, it becomes natural to extend HIL approaches to tester development. By replacing a physical unit with a proxy model deployed to a real-time or pseudo real-time target, test systems can be developed in parallel with the design and fabrication of a first production unit. This saves considerable time in the life cycle from conceptual design to realized product. This manuscript demonstrates the process flow using a capacitive discharge unit as an exemplar.

42 ENGINEERING↗