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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 OSTI2023

FY23 Update: Surface Sampling Activities for the Canister Deposition Field Demonstration

This report describes the results of a field demonstration of the proposed surface sampling techniques and plan for the multi-year Canister Deposition Field Demonstration (CDFD). The CDFD will evaluate salt deposition rates on three commercial 32PTH2 NUHOMS welded stainless steel storage canisters in Advanced Horizontal Storage Modules. Exposure testing is planned for up to 10 years and will incorporate periodic surface sampling campaigns. The goal of the planned dust sampling and analysis is to determine important environmental parameters that impact the potential occurrence of stress corrosion cracking on spent nuclear fuel (SNF) dry storage canisters. Specifically, measured dust deposition rates and deposited particle sizes will improve parameterization of dust deposition models employed to predict the potential occurrence and timing of stress corrosion cracks on the stainless steel SNF canisters. Previously, a preliminary sampling plan was developed, identifying possible sampling locations on the canister surfaces and sampling intervals; possible sampling methods were also described. Building from previous work, this report documents hand sampling from a spent nuclear fuel canister on a transfer skid mockup designed by Sandia National Laboratories. The sampling took place from a boom lift and salts were collected from mounted sample plates. The results of these efforts are presented in this report and compared to previous laboratory-controlled tests. The information obtained from the CDFD will be critical for ongoing efforts to develop a detailed understanding of the potential for stress corrosion cracking of SNF dry storage canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Lab-scale Production of Coal-derived Graphene Particle Bonded Filaments

The main goal of the project was to develop a lab-scale manufacturing process to fabricate filaments with high carbon content for Fused Deposition Modeling (FDM) three-dimensional (3D) printing use. Graphene particles derived from domestic US coal waste was used as feedstock for filament development.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

A Novel Dynamic Polymer Synthesis via Chlorinated Solvent Quenched Depolymerization

Dynamic polymers with both physical interactions and dynamic covalent bonds exhibit superior performance while achieving such dry polymers in an efficient manner remains a challenge. Herein, we report a novel organic solvent quenched polymer synthesis using a natural molecule, i.e., thioctic acid (TA), which has both dynamic disulfide bond and carboxylic acid. The effects of the solvent types and concentrations along with reaction times on the proposed reaction have been thoroughly explored for polymer synthesis. Solid-state proton nuclear magnetic resonance ( 1 H NMR) and first-principles simulations are carried out to investigate the reaction mechanism. It shows that the chlorinated solvent can efficiently stabilize and mediate the depolymerization of poly(TA) which is more kinetically favorable upon lowering the temperature. Attributed to the numerous dynamic covalent disulfide bonds and noncovalent hydrogen bonding, the obtained poly(TA) shows high extensibility, self-healable and re-processable properties. It can also be employed as an efficient adhesive even on a Teflon surface and 3D printed using the fused deposition modeling (FDM) technique. This new polymer synthesis approach on using organic solvents as catalysts along with the unique reaction mechanism provides a new pathway for efficient polymer synthesis, especially for those multi-functional dynamic polymers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗
NASA NTRS1976

Origin of the Apollo 17 deep drill coarse-grained layer

A depositional model of the coarse-grained layer of the Apollo 17 deep drill is described which takes into account thermoluminescence, tracks, Na-22 and Al-26 studies. On the basis of this evidence, it appears that the coarse-grained layer was emplaced some 100 m.y. ago associated either with Camelot Crater or the Central Cluster craters; at that time it was capped by some 25 cm of material which were recently (about 2 m.y.) excavated. The resulting depression has partially and gradually filled since.

Crozaz, G.↗
NASA NTRS1977

Environment effects from SRB exhaust effluents: Technique development and preliminary assessment

Techniques to determine the environmental effects from the space shuttle SRB (Solid Rocket Booster) exhaust effluents are used to perform a preliminary climatological assessment. The exhaust effluent chemistry study was performed and the exhaust effluent species were determined. A reasonable exhaust particle size distribution is constructed for use in nozzle analyses and for the deposition model. The preliminary assessment is used to identify problems that are associated with the full-scale assessment; therefore, these preliminary air quality results are used with caution in drawing conclusion regarding the environmental effects of the space shuttle exhaust effluents.

Goldford, A. I.↗
NASA NTRS1975

Rare gases and Ca, Sr, and Ba in Apollo 17 drill-core fines

Trapped gas isotopic compositions and spallation gas concentrations as functions of depth in the Apollo 17 drill core were determined from mass spectrometer studies by means of correlation techniques. The distribution of He, Ne, Ar, Kr, and Xe as well as Ca, Sr, and Ba was investigated, and rare-gas spallation and neutron capture profiles are compared with attention to proposed depositional models for the Taurus-Littrow regolith. The data exclude a sedimentation pattern similar to that found at the Apollo 15 site but are possibly compatible with long-term continuous accretion models or models of very recent rapid accumulation of regolith.

Pepin, R. O.↗
NASA NTRS1979

Particle deposition due to turbulent diffusion in the upper respiratory system

Aerosol deposition in the upper respiratory system (trachea to segmental bronchi) is considered and the importance of turbulent diffusion as a deposition mechanism is evaluated. It is demonstrated that for large particles (diameter greater than about 5 microns), turbulent diffusion is the dominant deposition mechanism in the trachea. Conditions under which turbulent diffusion may be important in successive generations of the pulmonary system are determined. The probability of particle deposition is compared with probabilities of deposition, as determined by the equations generally used in regional deposition models. The analysis is theoretical; no new experimental data is presented.

Hamill, P.↗
NASA NTRS1980

Apollo 17 drive tube 76001 - Modal petrology

Twelve polished thin sections from Apollo 17 drive tube 76001 have been studied by optical petrography. The entire core is found to be mature showing little variation in depth, which is consistent with a depositional model involving slow downslope movement of the regolith by mass wasting. However, within the core some major differences are preserved between two stratigraphic units. Unit A (20-31 cm depth) is enriched in gabbroic anorthosite relative to unit B (0-20 cm depth), while unit B is enriched in KREEPY noritic breccias relative to unit A. This observation is interpreted in terms of a stratigraphy for North Massif involving a noritic breccia unit overlying a unit enriched in gabbroic anorthosite. Pronounced differences between the highland/mare ratios in drive tube 76001 and the Apollo 17 drill core separated by only 3.5 km demonstrate the relative inefficiency of lateral transport as a regolith mixing mechanism on the moon.

Papike, J. J.↗
NASA NTRS1984

Surface protection

The surface protection subproject consists of three major thrusts: airfoil deposition model; metallic coating life prediction; and thermal barrier coating (TBC) life prediction. The time frame for each of these thrusts and the expected outputs are presented. Further details are given for each thrust such as specific element schedules and the status of performance; in-house, via grant, or via contract.

Levine, S. R.↗
NASA NTRS1987

Status of indium phosphide solar cell development at Spire

On-going development of indium phosphide solar cells for space applications is presented. The development is being carried out with a view towards both high conversion efficiency and simplicity of manufacture. The cell designs comprise the ion-implanted cell, the indium tin oxide top contact cell, and the epitaxial cell grown by metal organic chemical vapor deposition. Modelling data on the limit to the efficiency are presented and comparison is made to measured performance data.

Spitzer, M. B.↗
NASA NTRS1991

Integration of optical and microwave images for geologic mapping and resource explorations

Multispectral images in the visible, near-IR, short-wave IR, thermal IR, and microwave regions, obtained during the Geologic Remote Sensing Field Experiment were combined with data from Landsat TM, laboratory, and field spectral measurements, as well as traditional geologic mapping and were used to produce thematic image maps showing details of the surface geology for an area at the north end of Death Valley (California/Nevada). The integrated multispectral images provide new geologic information which can be used in mineral deposit models to provide exploration targets. The data demonstrated the relationship between the surface composition of materials and remote sensing in the visible and infrared.

Kruse, Fred A.↗
NASA NTRS2010

J-2X Test Articles Using FDM Process

This viewgraph presentation gives a brief history of the J-2X engine, along with detailed description of the material demonstrator and test articles that were created using Fused Deposition Modeling (FDM) process.

Anderson, Ted↗
NASA NTRS2012

The Multiple Use Plug Hybrid for NanoSats (MUPHyN) Miniature Thruster

The Multiple Use Plug Hybrid (for) Nanosats is a prototype thruster is being developed to fill a niche application for NanoSat-scale spacecraft propulsion. When fully developed, the MUPHyN thruster will provide an effective and low-risk propulsive capability that could enable multiple NanoSats to be independently re-positioned after deployment from a parent launch vehicle. Because the environmentally benign, chemically-stable propellants are mixed only within the combustion chamber after ignition and the flow rate of the fuel is determined by a pyrolysis mechanism that is nearly independent of pressure or fuel grain defects, the system is inherently safe and can be piggy-backed near a secondary payload with little or no overall mission risk increase to the primary payload. The MUPHyN thruster uses safe-handling and inexpensive nitrous oxide (N2O) and acrylonitrile-butadiene-styrene (ABS) as propellants. Fused Deposition Modeling (FDM), a direct digital manufacturing process, is used to fabricate short-form-factor solid fuel grains with multiple helical combustion ports from ABS thermoplastic. This manufacturing process allows for the rapid development and manufacture of complex fuel grain geometries that are not possible to extrude or cast using conventional methods. This technology enables the construction of fuel grains with length-to-diameter ratios appropriate for incorporation into CubeSats while maintaining high surface areas and regression rates that allow the system to maintain a near optimal oxidizer to fuel ratio. The MUPHyN system provides attitude control torques by using secondary-injection thrust vectoring on a truncated aerospike nozzle. This configuration allows large impulse delta V burns and small impulse attitude control firings to be performed with the same system. To ensure survivability during extend duration burns, the MUPHyN incorporates a novel regenerative cooling design where the N2O oxidizer flows through a cooling path embedded in the aerospike nozzle before being injected into the combustion chamber near the nozzle base.

Eilers, Shannon D.↗
NASA NTRS2014

Enabling Technologies for Entrepreneurial Opportunities in 3D printing of SmallSats

A consortium of innovative experts in additive manufacturing (AM) comprising Northrup Grumman Technical Services, University of Texas at El Paso (UTEP), Configurable Space Microsystems Innovations & Applications Center (COSMIAC), NASA Glenn Research Center (GRC), and Youngstown State University, have made significant breakthroughs in the goal of creating the first complete 3D printed small satellite. Since AM machines are relatively inexpensive, this should lead to many entrepreneurial opportunities for the small satellite community. Our technology advancements are focused on the challenges of embedding key components within the structure of the article. We have demonstrated, using advanced fused deposition modeling techniques, complex geometric shapes which optimize the spacecraft design. The UTEP Keck Center has developed a method that interrupts the printing process to insert components into specific cavities, resulting in a spacecraft that has minimal internal space allocated for what traditionally were functional purposes. This allows us to increase experiment and instrument capability by provided added volume in a confined small satellite space. Leveraging initial progress made on a NASA contract, the team investigated the potential of new materials that exploit the AM process, producing candidate compositions that exceed the capabilities of traditional materials. These "new materials" being produced and tested include some that have improved radiation shielding, increased permeability, enhanced thermal properties, better conductive properties, and increased structural performance. The team also investigated materials that were previously not possible to be made. Our testing included standard mechanical tests such as vibration, tensile, thermal cycling, and impact resistance as well as radiation and electromagnetic tests. The initial results of these products and their performance will be presented and compared with standard properties. The new materials with the highest probability to disrupt the future of small satellite systems by driving down costs will be highlighted, in conjunction with the electronic embedding process.

Communications↗
NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗