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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Process-level cost analysis of hybrid manufacturing pathways for aerospace structural components

Hybrid manufacturing is a promising route for producing complex aerospace components, yet systematic cost benchmarking across multiple additive-subtractive pathways remains limited. This study presents a comprehensive process-based cost analysis of seven hybrid manufacturing routes, including laser powder bed fusion (L-PBF), powder- and wire-directed energy deposition (DED), wire arc additive manufacturing (WAAM), additive friction stir deposition (AFSD), metal binder jetting (MBJ), and agility forging, followed by scanning and finish machining. Parametric cost models incorporating direct material, labor, and energy costs were developed. L-PBF results are discussed in detail for a pickle fork component and directly compared with commercial pricing. Across all hybrid routes, labor emerged as the dominant cost driver, contributing more than 70% of total manufacturing cost in some cases. AFSD exhibited the lowest cost for aluminum components, with MBJ being its 316 L stainless steel counterpart, after accounting for geometric scaling. Benchmarking against industrial quotes suggests that hybrid manufacturing can achieve cost levels comparable to those of commercial services, although labor-intensive processes exhibit greater deviation. The analysis highlights automation of material handling, setup, and supervision as key opportunities for improving economic competitiveness. Overall, the proposed framework provides a quantitative basis for evaluating and optimizing hybrid manufacturing pathways for aerospace applications.

Baruah, Sweta [ORNL] (ORCID:0009000174256207)↗
DOE OSTI2024

Snow Distribution Patterns Revisited: A Physics-Based and Machine Learning Hybrid Approach to Snow Distribution Mapping in the Sub-Arctic

Snowpack distribution in Arctic and alpine landscapes often occurs in repeating, year-to-year patterns due to local topographic, weather, and vegetation characteristics. Previous studies have suggested that with years of observational data, these snow distribution patterns can be statistically integrated into a snow process modeling workflow. Recent advances in snow hydrology and machine learning (ML) have increased our ability to predict snowpack distribution using in-situ observations, remote sensing data sets, and simple landscape characteristics that can be easily obtained for most environments. Here, we propose a hybrid approach to couple a ML snow distribution pattern (MLSDP) map with a physics-based, snow process model. We trained a random forest ML algorithm on tens of thousands of snow survey observations from a subarctic study area on the Seward Peninsula, Alaska, collected during peak snow water equivalent (SWE). We validated hybrid model outputs using in-situ snow depth and SWE observations, as well as a light detection and ranging data set and a distributed temperature profiling sensor data set. When the hybrid results were compared with the physics-based method, the hybrid method more accurately depicted the spatial patterns of the snowpack, areas of drifting snow, and years when no in-situ observations were used in the random forest ML training data set. The hybrid method also showed improvements in root mean squared error at 61% of locations where time-series estimations of snow depth were observed. These results can be applied to any physics-based model to improve the snow distribution patterning to reflect observed conditions in high latitude and high elevation cold region environments.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Dual interfacial H-bonding-enhanced deep-blue hybrid copper–iodide LEDs

Solution-processed light-emitting diodes based on non-toxic copper–iodide hybrids are a compelling solution for efficient and stable deep-blue lighting, owing to their tunability, high photoluminescence efficiency and environmental sustainability. Here we present a hybrid copper–iodide that shows near-unity photoluminescence quantum yield (99.6%) with an emission wavelength of 449 nm and colour coordinates (0.147, 0.087), alongside its emission mechanism and charge transport characteristics. Here, we use the thin film of this hybrid as the sole active emissive layer to fabricate deep-blue light-emitting diodes and subsequently enhance the device performance through a dual interfacial hydrogen-bond passivation strategy. This synergetic surface modification approach, integrating a hydrogen-bond-acceptor self-assembled monolayer with an ultrathin polymethyl methacrylate capping layer, effectively passivates both heterojunctions of the copper–iodide hybrid emissive layer and optimizes charge injections. We achieve a maximum external quantum efficiency of 12.57%, a maximum luminance of 3,970.30 cd m −2 with colour coordinates (0.147, 0.091) and an excellent operational stability (half-lifetime) of 204 hours under ambient conditions. We further showcase a large-area device of 4 cm 2 that maintains high efficiency. Our findings reveal the potential of copper–iodide-based hybrid materials for applications in solid-state lighting and display technologies, offering a versatile strategy for enhancing device performances.

14 SOLAR ENERGY↗
DOE OSTI2025

A Computational Procedure for Assessing I$_{c}(\varepsilon$) in Nb$_{3}$Sn/Bi-2212 Hybrid Magnets

The critical current of superconductors is commonly measured by testing unloaded wires under an external magnetic field. While stressed by intense Lorentz forces, the existing HTS/LTS superconductors are prone to a reduction in critical current before reaching their structural mechanical limit. Here, in this work, the magnetic and mechanical analysis of the FNAL 4-layer Bi-2212/Nb$_{3}$Sn hybrid dipole magnet is reported, aimed at predicting the critical current degradation for both the superconductors during powering at 16T. All the Rutherford cables in the coils of the hybrid magnet were modeled at the strand level in Ansys APDL with the heterogeneous cable model. Utilizing this detailed geometry, it was possible to evaluate the effects of strain on the critical current degradation for both the Nb$_{3}$Sn and Bi-2212 superconductors under the intense Lorentz forces. The analysis presented in this paper integrates strain-dependent critical current laws, with parameters derived from experimental data, to simulate the hybrid magnet's performance for all possible current-powering configurations. The proposed methodology enables a detailed assessment of conductor integrity and I$_{C}(\varepsilon$) reduction in existing hybrid magnet designs, providing a versatile and rigorous framework for optimizing future high-field hybrid magnets.

D'Agliano, A. [Lawrence Berkeley National Laborato↗
DOE OSTI2024

Hybrid Power Plants: Status of Operating and Proposed Plants, 2024 Edition [Slides]

Improving battery technology and the growth of variable renewable generation are driving a surge of interest in “hybrid” power plants that combine, for example, wind or solar generating capacity with co-located batteries. While most of the current interest involves pairing photovoltaic (PV) plants with batteries, other types of hybrid or co-located plants with wide-ranging configurations have been part of the U.S. electricity mix for decades. This annually updated briefing tracks and maps existing hybrid or co-located plants across the United States while also synthesizing data from power purchase agreements (PPAs) and generation interconnection queues to shed light on near- and long-term development pipelines. The scope includes “co-located hybrids” that pair two or more resources (e.g., multiple types of generation and/or generation with storage) that are operated largely independently behind a single point of interconnection, and “full hybrids” that also feature coordinated operations of the co-located resources. The focus is on plants with one megawatt (MW) or more of capacity; smaller (often behind-the-meter) projects are also increasingly common, but are not included in this data synthesis.

14 SOLAR ENERGY↗
DOE OSTI2025

Hybrid Metal Halides: Advancing Optoelectronic Materials (Final Technical Report)

Hybrid metal halides, particularly main group halide perovskites, are a unique class of materials that offer exceptional optoelectronic properties along with a remarkable materials design space. Initial research on this class of materials was driven by the ability of the prototype hybrid 3D perovskite-structured compound methylammonium lead iodide to function as the active layer in thin film solar cells. It is now known that this class of materials comprise a large family with tunable band gaps, relatively high charge carrier mobilities in both single crystal and polycrystalline forms, and relatively low concentrations of (deleterious) electrically active states within the band gap. Beyond applications in solar cells, the potential of these materials has been extended to emitters in light emitting diodes, and active components of radiation detectors. Complementing new functionality, the design space for hybrid metal halides continues to increase with discovery of new structural motifs. In this project, the combination of organic and inorganic functionalities has been employed to open pathways to the design and synthesis new, functional hybrid metal halides. Beyond the simple perovskites, Ruddlesden-Popper and Dion-Jacobsen compounds, and other variants, such as the newly advanced “hollow” perovskites have been studied. The materials have provided routes to understanding the unique electronic properties of hybrid metal halides because of their natural quantum well structures as well as other means of controlling band gaps and band dispersions. Understanding these materials, including the design rules for their formation, their structures and compositions in bulk and in thin films form, and the role of local (non-crystallographic) structure has an important aspect of this endeavor. The goal of advancing new materials and new fundamental understanding within this deceptively simple, yet fascinating class of compounds, so richly endowed with interesting and useful functionality, has been fulfilled.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior

Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
DOE OSTI2026

HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION

The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

Wasti, Sanjita [ORNL]↗
NASA NTRS1974

Real-time simulation of the TF30-P-3 turbofan engine using a hybrid computer

A real-time, hybrid-computer simulation of the TF30-P-3 turbofan engine was developed. The simulation was primarily analog in nature but used the digital portion of the hybrid computer to perform bivariate function generation associated with the performance of the engine's rotating components. FORTRAN listings and analog patching diagrams are provided. The hybrid simulation was controlled by a digital computer programmed to simulate the engine's standard hydromechanical control. Both steady-state and dynamic data obtained from the digitally controlled engine simulation are presented. Hybrid simulation data are compared with data obtained from a digital simulation provided by the engine manufacturer. The comparisons indicate that the real-time hybrid simulation adequately matches the baseline digital simulation.

Szuch, J. R.↗
NASA NTRS1975

Contamination control in hybrid microelectronic modules. Part 3: Specifications for coating material and process controls

Resin systems for coating hybrids prior to hermetic sealing are described. The resin systems are a flexible silicone junction resin system and a flexible cycloaliphatic epoxy resin system. The coatings are intended for application to the hybrid after all the chips have been assembled and wire bonded, but prior to hermetic sealing of the package. The purpose of the coating is to control particulate contamination by immobilizing particles and by passivating the hybrid. Recommended process controls for the purpose of minimizing contamination in hybrid microcircuit packages are given. Emphasis is placed on those critical hybrid processing steps in which contamination is most likely to occur.

Himmel, R. P.↗
NASA NTRS1975

Evaluation of all-parachute and hybrid /parachute-retrorocket/ recovery systems for a one-million-pound booster

Both an all-parachute recovery system and a hybrid parachute-retrorocket recovery system for a one-million-pound booster are evaluated in order to determine what parachute sizes and number in a cluster are required for an all-parachute system to provide impact velocities of less than 100 ft/sec and in order to determine whether the hybrid system permits a weight reduction over an all-parachute system. A minimum-weight hybrid decelerator system using Kevlar materials for a cluster of three parachutes with two stages of reefing is analyzed. Major conclusions are that for an impact velocity of less than 100 ft/sec the hybrid decelerator system is lighter in weight, and that the use of Kevlar rather than Nylon material results in hybrid decelerator system weight savings of over 40% for impact velocities in the range 60-30 ft/sec.

Eckstrom, C. V.↗
NASA NTRS1977

Hybrid composites - State-of-the-art review: Analysis, design, application and fabrication

The review covers hybrid composites that consist of two or more different types of fibers (or fiber composites) in a frequently repeated pattern in a laminate. The fibers considered are boron, graphite, glass, and Kevlar; the resins considered include mostly structural epoxies, with some utilization of polyimides and thermoplastics. The review shows that considerable data have been generated for the tensile strength properties, as well as tensile and thermal fatigue, of interply hybrids, and for the impact resistance of interply and intraply hybrids. The rule of mixtures appears to be adequate for predicting longitudinal and transverse mechanical properties of unidirectional interply hybrids, and linear laminate theory appears to be adequate for predicting the elastic response of hybrids.

Chamis, C. C.↗
NASA NTRS1979

An isentropic and sigma coordinate hybrid numerical model - Model development and some initial tests

A solution is presented for matching boundary conditions across the interface of an isentropic and sigma coordinate hybrid model. A hybrid model based on the flux form of the primitive equations is developed which allows direct vertical exchange between the model domains, satisfies conservation principles with respect to transport processes, and maintains a smooth transition across the interface without need for artificial adjustment or parameterization schemes. The initial hybrid model simulations of a jet streak propagating in a zonal channel are used to test the feasibility of the hybrid model approach. High efficiency of the hybrid model is demonstrated.

Uccellini, L. W.↗
NASA NTRS1980

Development of LaRC 160/NR150B2 polyimide graphite hybrid composites

A method for co-curing NR150B2 and LaRC 160 prepregs into hybrid composites was developed. The processing characteristics and the properties of the hybrid composites were compared with those of laminates fabricated from the individual component prepregs. Resin forms were selected and optimized and a new NR150 formulation was investigated. The new formulation greatly facilitated the processing and the performance of this system. Quality control techniques were evaluated and developed, high quality laminates were fabricated from both individual resin systems, and hybrid laminates were successfully co-cured. Optimum hybrid forms were investigated and several novel approaches were explored. An optimum hybrid system was developed that utilizes a LaRC curing schedule but shows no degradation of mechanical properties after aging 500 hr in air at 260 C.

Maximovich, M. G.↗
NASA NTRS1979

Mechanical property characterization of intraply hybrid composites

An investigation of the mechanical properties of intraply hybrids made from graphite fiber/epoxy matrix hybridized with secondary S-glass or Kevlar 49 fiber composites is presented. The specimen stress-strain behavior was determined, showing that mechanical properties of intraply hybrid composites can be measured with available methods such as the ten-degree off-axis test for intralaminar shear, and conventional tests for tensile, flexure, and Izod impact properties. The results also showed that combinations of high modulus graphite/S-glass/epoxy matrix composites exist which yield intraply hybrid laminates with the best 'balanced' properties, and that the translation efficiency of mechanical properties from the constituent composites to intraply hybrids may be assessed with a simple equation.

Chamis, C. C.↗
NASA NTRS1984

Real-time hybrid computer simulation of a small turboshaft engine and control system

The development of an analytical model of a small turboshaft engine designed for helicopter propulsion systems is described. The model equations were implemented on a hybrid computer system to provide a real time nonlinear simulation of the engine performance over a wide operating range. The real time hybrid simulation of the engine was used to evaluate a microprocessor based digital control module. This digital control module was developed as part of an advanced rotorcraft control program. After tests with the hybrid engine simulation the digital control module was used to control a real engine in an experimental program. A hybrid simulation of the engine's electrical hydromechanical control system was developed. This allowed to vary the fuel flow and torque load inputs to the hybrid engine simulation for simulating transient operation. A steady-state data and the experimental tests are compared. Analytical model equations, analog computer diagrams, and a digital computer flow chart are included.

Hart, C. E.↗
NASA NTRS1988

Modified hybrid control of robot manipulators for high precision assembly operations

This paper is concerned with applications of robot manipulators in high precision assembly tasks that can be successfully performed by employing a hybrid control scheme that independently controls force and position. A traditional hybrid control scheme is implemented in Cartesian space. In the modified hybrid control scheme introduced in this paper, the error driven control signals are expressed in joint space. This paper studies the implementation of the modified hybrid control scheme on a two-degree-of-freedom robot manipulator with a closed-kinematic chain mechanism. The performance of the traditional and modified hybrid control schemes is comparatively evaluated by computer simulation in terms of computation time and accuracy for several study cases.

Nguyen, Charles C.↗
NASA NTRS1990

Hybrid propulsion technology program

Technology was identified which will enable application of hybrid propulsion to manned and unmanned space launch vehicles. Two design concepts are proposed. The first is a hybrid propulsion system using the classical method of regression (classical hybrid) resulting from the flow of oxidizer across a fuel grain surface. The second system uses a self-sustaining gas generator (gas generator hybrid) to produce a fuel rich exhaust that was mixed with oxidizer in a separate combustor. Both systems offer cost and reliability improvement over the existing solid rocket booster and proposed liquid boosters. The designs were evaluated using life cycle cost and reliability. The program consisted of: (1) identification and evaluation of candidate oxidizers and fuels; (2) preliminary evaluation of booster design concepts; (3) preparation of a detailed point design including life cycle costs and reliability analyses; (4) identification of those hybrid specific technologies needing improvement; and (5) preperation of a technology acquisition plan and large scale demonstration plan.

Source record↗