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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

3D nanolithography with metalens arrays and spatially adaptive illumination

The growing demand for advanced materials, miniaturized devices and integrated microsystems calls for the reliable fabrication of complex, multiscale, three-dimensional (3D) architectures, a need increasingly addressed through light-based and laser-based processes. However, owing to the field-of-view (FOV) limitations of conventional imaging optics, existing 3D laser nanofabrication techniques face fundamental challenges in throughput, proximity error and stitching defects on the path to scaling. Here, in this study, we present a scalable 3D nanofabrication platform that uses a metalens-generated focal spot array to parallelize two-photon lithography (TPL) beyond centimetre-scale write field areas. Metalenses are ideally suited for producing submicron-scale focal spots for high-throughput nanolithography, as they uniquely feature large numerical apertures (NAs), immersion media compatibility and large-scale manufacturability. We experimentally demonstrate a printing system that uses a 12-cm 2 metalens array to produce more than 120,000 cooperative focal spots, corresponding to a throughput exceeding 10 8 voxels s −1 . By programmatically patterning the focal spot array using a spatial light modulator (SLM), an adaptive parallel printing strategy is developed for precise greyscale linewidth modulation and choreographed printing of semiperiodic and fully aperiodic 3D geometries. We demonstrate parallel printing of replicated microstructures (>50 M microparticles per day), centimetre-scale 3D architectures with feature sizes down to 113 nm, and photonic and mechanical metamaterials. This work demonstrates the potential of 3D nanolithography towards wafer-scale production, showing how TPL could be used at scale for applications in microelectronics, biomedicine, quantum technology and high-energy laser targets.

Materials science↗
NASA NTRS2010

Adaptable Holders for Arc-Jet Screening Candidate Thermal Protection System Repair Materials

Reusable holders have been devised for evaluating high-temperature, plasma-resistant re-entry materials, especially fabrics. Typical material samples tested support thermal-protection-system damage repair requiring evaluation prior to re-entry into terrestrial atmosphere. These tests allow evaluation of each material to withstand the most severe predicted re-entry conditions.

Riccio, Joe↗
NASA NTRS2023

Damage Tolerance Comparison of IM7/8552 and T1100/3960 Carbon Fiber/Epoxy Sandwich Structure in Support of the Space Launch System Payload Adapter Fitting

As technology evolves and improves within the science of composite materials, new fiber/ resin systems are being developed for improved properties given certain loading and environmental scenarios. Improving the room temperature damage tolerance capabilities has long been one of the goals in the carbon fiber/polymer composite industry. Recently a new fiber/epoxy system has been introduced that is claimed to have superior damage tolerance capabilities. To examine if this new carbon fiber/epoxy composite material would be of benefit to a program to manufacture a Payload Adapter Fitting (PAF) for NASA’s Space Launch System (SLS) rocket, the question was asked as to just how much damage tolerance could be realized if this new system were used. Compression after impact (CAI) strength of sandwich structure is one of the leading metrics being used to evaluate materials for the PAF program. As a result, a comparison of this new fiber/resin system with a very common (and planned baseline) fiber/resin system with respect to CAI was considered in this study. While it was already known that the older, baseline carbon fiber structure would not have as good damage tolerance characteristics as the newer carbon fiber system, the quantitative difference in damage tolerance was sought in this study since no other CAI data could be found in open literature on sandwich structures made with this new fiber/resin system.

A.T. Nettles↗
NASA NTRS1975

Reflective superinsulation materials

Reflective superinsulation films are gradually being adapted for use in civilian thermal products. A wide range of their applications in emergency equipment and lightweight clothing is described.

Source record↗
DOE OSTI2025

Generating forces in confinement via polymerization

Understanding how to produce forces using biomolecular building blocks is essential for the development of adaptive synthetic cells and living materials. Here we ask whether a dynamic polymer system can generate deformation forces in soft shells by pure self-assembly, motivated by the fact that biological polymer networks like the cytoskeleton can exert forces, move objects, and deform membranes by simply growing, even in the absence of molecular motors. We address this question by investigating polymer force generation by varying the release rate, the structure, and the interactions of self-assembling monomers. First, we develop a toy computational model of polymerization in a soft elastic shell that reveals the emergence of spontaneous bundling which enhances shell deformation. We then extend our model to account more explicitly for monomer binding dynamics. We find that the rate at which monomers are released into the interior of the shell is a crucial parameter for achieving deformation through polymer growth. Lastly, we demonstrate that the introduction of multivalent particles that can join polymers can either improve or impede polymer performance, depending on the amount and on the structure of the multivalent particles. Our results provide guidance for the experimental realization of polymer systems that can perform work at the nanoscale, for example through rationally designed self-assembling proteins or nucleic acids.

Osmanović, Dino [University of California at Los A↗
DOE OSTI2024

A recyclable self-healing composite with advanced sensing property

Polymer-based composites frequently encounter damage, often lurking beneath the surface and proving challenges to their early detection and repair. While material-based sensors show promise for encoding self-sensing properties within these composites, their in situ healing and reprocessability remain significant challenges. Therefore, the overarching goal of this study is the creation of a reprocessable polymeric composite encoded with self-healing attributes and the ability to autonomously sense damage. At the core of this innovation are vitrimers, a polymeric material characterized by a covalently adaptive dynamic network responsive to external factors such as heat. They combine thermoset-like resilience with thermoplastic-like flowability on demand under external stimuli. We nanoengineer a polyester-based vitrimeric polymer by incorporating piezoresistive carbon nanotubes (CNTs) as reinforcing elements that not only enhance its mechanical strength but also create a percolation network within the composite, thereby enabling piezoresistive self-sensing properties, all the while preserving the intrinsic self-healing capabilities offered by the vitrimeric matrix. The fabrication process of the composite involves a solvent-free in situ polymerization method that combines epoxy and anhydride-containing monomers with ~ 0.1 wt.% of CNTs. Once it was established that the introduction of CNTs into the polymeric matrix did not compromise the mechanical properties of the composite, their strain-sensing properties were characterized by applying cyclic loading while measuring their electrical resistance. Strikingly, CNT-enhanced vitrimer composite consistently retains its mechanical and sensing properties through repeated cycles of reshaping and reprocessing, underscoring its potential as a robust distributed strain sensor. This polyester-based vitrimeric composite is also easily recyclable without harsh chemical treatments. Preliminary findings from this study conclusively demonstrate that the bulk composite boasts both self-sensing capabilities and in situ detect healing properties, charting a promising course towards the development of a mechanically resilient multifunctional composite that seamlessly integrates selfsensing and healing capabilities.

Rohewal, Sargun Singh↗
NASA NTRS1989

Thin-film sensors for reusable space propulsion systems

Thin-film thermocouples (TFTCs) were developed for aircraft gas turbine engines and are in use for temperature measurement on turbine blades up to 1800 F. Established aircraft engine gas turbine technology is currently being adapted to turbine engine blade materials and the environment encountered in the Space Shuttle Main Engine (SSME)-severe thermal shock from cryogenic fuel to combustion temperatures. Initial results with coupons of MAR M-246 (+Hf) and PWA 1480 were followed by fabrication of TFTC on SSME turbine blades. Current efforts are focused on preparation for testing in the Turbine Blade Tester at NASA Marshall Space Flight Center.

Hepp, Aloysius F.↗
NASA NTRS1990

Robot dynamics in reduced gravity environment

Robot dynamics and control will become an important issue for productive platforms in space. Robotic operations will be necessary for both man tended stations and for the efficient performance of routine operations in a manned platform. The current constraints on the use of robotic devices in a microgravity environment appears to be due to safety concerns and an anticipated increase in acceleration levels due to manipulator motion. The robot used for the initial studies was a UMI RTX robot, which was adapted to operate in a materials processing workcell to simulate sample changing in a microgravity environment. The robotic cell was flown several times on the KC-135 aircraft at Ellington Field. The primary objective of the initial flights was to determine operating characteristics of both the robot and the operator in the variable gravity of the KC-135 during parabolic maneuvers. It was demonstrated that the KC-135 aircraft can be used for observing dynamics of robotic manipulators. The difficulties associated with humans performing teleoperation tasks during varying G levels were also observed and can provide insight into some areas in which the use of artificial techniques would provide improved system performance. Additionally a graphic simulation of the workcell was developed on a Silicon Graphics Workstation using the IGRIP simulation language from Deneb Robotics. The simulation is intended to be used for predictive displays of the robot operating on the aircraft. It is also anticipated that this simulation can be useful for off-line programming of tasks in the future.

Workman, Gary L.↗
NASA NTRS1989

Thin-film sensors for space propulsion technology: Fabrication and preparation for testing

The goal of this work is to develop and test 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 up to 1800 F. Established aircraft engine gas turbine technology is currently being adapted to turbine engine blade materials and the environment encountered in the SSME, especially severe thermal shock from cryogenic fuel to combustion temperatures. Initial results using coupons of MAR M-246 (+Hf) and PWA 1480 have been followed by fabrication of thin-film thermocouples on SSME turbine blades. Current efforts are focused on preparing for testing in the Turbine Blade Tester at the NASA Marshall Space Flight Center (MSFC). Future work will include testing of thin-film thermocouples on SSME blades of single crystal PWA 1480 at MSFC.

Kim, Walter S.↗
NASA NTRS1994

Probabilistic assessment of uncertain adaptive hybrid composites

Adaptive composite structures using actuation materials, such as piezoelectric fibers, were assessed probabilistically utilizing intraply hybrid composite mechanics in conjunction with probabilistic composite structural analysis. Uncertainties associated with the actuation material as well as the uncertainties in the regular (traditional) composite material properties were quantified and considered in the assessment. Static and buckling analyses were performed for rectangular panels with various boundary conditions and different control arrangements. The probability density functions of the structural behavior, such as maximum displacement and critical buckling load, were computationally simulated. The results of the assessment indicate that improved design and reliability can be achieved with actuation material.

Shiao, Michael C.↗
NASA NTRS2002

Demonstration of Advanced C/SiC Cooled Ramp

Under a NASA contract, SPS is evaluating its C/SiC to metal brazing technique for the development of light, composite, actively cooled panels. The program first consisted of defining a system applicable to the X-33 nozzle ramp. SPS then performed evaluation tests for tube, composite, and braze material selection, and for the adaptation of braze process parameters to the parts geometry. SPS is presently manufacturing a 250x60 millimeter squared specimen, including 10 metallic tubes, which will be cycled in the NASA/GRC-CELL-22 test bed under engine representative conditions.

Bouquet, Clement↗
NASA NTRS2012

Absolute Position of Targets Measured Through a Chamber Window Using Lidar Metrology Systems

Lidar is a useful tool for taking metrology measurements without the need for physical contact with the parts under test. Lidar instruments are aimed at a target using azimuth and elevation stages, then focus a beam of coherent, frequency modulated laser energy onto the target, such as the surface of a mechanical structure. Energy from the reflected beam is mixed with an optical reference signal that travels in a fiber path internal to the instrument, and the range to the target is calculated based on the difference in the frequency of the returned and reference signals. In cases when the parts are in extreme environments, additional steps need to be taken to separate the operator and lidar from that environment. A model has been developed that accurately reduces the lidar data to an absolute position and accounts for the three media in the testbed air, fused silica, and vacuum but the approach can be adapted for any environment or material. The accuracy of laser metrology measurements depends upon knowing the parameters of the media through which the measurement beam travels. Under normal conditions, this means knowledge of the temperature, pressure, and humidity of the air in the measurement volume. In the past, chamber windows have been used to separate the measuring device from the extreme environment within the chamber and still permit optical measurement, but, so far, only relative changes have been diagnosed. The ability to make accurate measurements through a window presents a challenge as there are a number of factors to consider. In the case of the lidar, the window will increase the time-of-flight of the laser beam causing a ranging error, and refract the direction of the beam causing angular positioning errors. In addition, differences in pressure, temperature, and humidity on each side of the window will cause slight atmospheric index changes and induce deformation and a refractive index gradient within the window. Also, since the window is a dispersive media, the effect of both phase and group indices have to be considered. Taking all these factors into account, a method was developed to measure targets through multiple regions of different materials and produce results that are absolute measurements of target position in three-dimensional space, rather than simply relative position. The environment in which the lidar measurements are taken must be broken down into separate regions of interest and each region solved for separately. In this case, there were three regions of interest: air, fused silica, and vacuum. The angular position of the target inside the chamber is solved using only phase index and phase velocity, while the ranging effects due to travel from air to glass to vacuum/air are solved with group index and group velocity. When all parameters are solved simultaneously, an absolute knowledge of the position of each target within an environmental chamber can be derived. Novel features of this innovation include measuring absolute position of targets through multiple dispersive and non-dispersive media, deconstruction of lidar raw data from a commercial off-the-shelf unit into reworkable parameters, and use of group velocities to reduce range data. Measurement of structures within a vacuum chamber or other harsh environment, such as a furnace, may now be measured as easily as if they were in an ambient laboratory. This analysis permits transformation of the raw data into absolute spatial units (e.g., mm). This technique has also been extended to laser tracker, theodolite, and cathetometer measurements through refractive media.

Kubalak, David↗
NASA NTRS2014

Resource Production on the Moon

A self-sustaining settlement on the moon, or on other airless bodies such as asteroids, will require the ability to refine desired raw materials from available resources, such as lunar or asteroidal regolith. This work will focus on the example case of pro-duction from lunar regolith. The same process sequences could be used at other locations. Stony asteroids typically have regolith similar to that of the moon, and refining of asteroidal material could use the same techniques, adapted for microgravity. Likewise, Martian rock and soil could also be processed by the techniques discussed here.

moon↗
NASA NTRS1985

Pantographing self adaptive gap elements

This paper develops a so-called pantographing self adaptive gap element type contact strategy. Due to the manner of formulation, the scheme has the capability to handle large deformations in the contact zone; contact initiation in structure exhibiting either positive or indefinite stiffness characteristics; kinematic and material nonlinearity as well as; self adaptively adjusts load/time stepping. In this context, contact in pre and postbuckling structure can be treated. To illustrate the scheme, several benchmark problems are presented. These include contacting structure involving large deformation kinematics, inelastic behavior as well as pre and postbuckling stiffness characteristics.

Padovan, J.↗
DOE OSTI2025

Assessing the Long-Term Stability of Anion Exchange Membranes for Electrochemical CO 2 Reduction

Materials and cell components used in CO 2 electrolysis have largely been adapted from technologies initially developed for water electrolysis and fuel cells. However, electrochemical CO 2 reduction introduces distinct material challenges due to the unique chemical environment in this process. Here, in this study, we conducted ex-situ 1000 h stability tests on commonly used anion exchange membranes, exposing them exclusively to electrolytes and organic molecules used or produced during CO 2 electrolysis, at concentrations relevant to and compatible with postseparation processes. Notably, 15% w/w n-propanol and 5 M acetic acid caused complete dissolution or partial disintegration of the membranes unless cross-linking was present and remained stable throughout the test. When the membranes stayed physically intact, most of them exhibited excellent chemical stability in alkaline medium containing alcohols or formic acid, which was confirmed by vibrational spectroscopy and ion exchange capacity measurements. However, exposure to alcohol-and acid-containing solutions led to a substantial increase in swelling and water uptake, with potential implications for mechanical stability, ion/product crossover, and compression management of adjacent components. The potential effects of CO 2 electroreduction products on membrane stability, their subsequent impact on electrolyzer performance, and mitigation strategies are discussed.

CO2RR↗
NASA NTRS1979

Abradable compressor and turbine seals, volume 1

The application and advantages of abradable coatings as gas-path seals in a general aviation turbine engine were evaluated for use on the high-pressure compressor, the high-pressure turbine, and the low-pressure turbine shrouds. Topics covered include: (1) the initial selection of candidate materials for interim full-scale engine testing; (2) interim engine testing of the initially selected materials and additional candidate materials; (3) the design of the component required to adapt the hardware to permit full-scale engine testing of the most promising materials; (4) finalization of the fabrication methods used in the manufacture of engine test hardware; and (5) the manufacture of the hardware necessary to support the final full-scale engine tests.

Sundberg, D. V.↗
NASA NTRS2006

International Education Opportunities during the IHY: Bridging the Geographic, Cultural and Linguistic Divide between Participating IHY Nations

Currently there are over 70 U.N. Member States participating in the International Heliophysical Year (IHY 2007- 8), and most of these nations do not use English as their primary language. The IHY contains four main program elements: Science, Observatory Development, Outreach, and History. For these elements to be successful, each requires successful communication within and adaptation for the individual member states. The IHY Outreach program contains many educational activities targeting a wide range of languages and contexts. The other three program elements, however, offer a means to extend the impact of the educational programs and reinforce educational activities. IHY's scientific activities involve partnerships with institutions and observatories, many of which have outreach activities in their local communities. Scientists and participation programs from around the world have begun translating materials into their local languages and adapting educational tools for use in their communities. IHY's Observatory Development program, which began deploying instrumentation worldwide in 2004, encourages a strong educational component to each new observatory site as a means of ensuring long-lasting viability of the research program. The history program gathers important information and educates the public about the development of space science. This presentation will discuss efforts occurring within the IHY program that support cross-cultural communication and education and present opportunities to reach new audiences.

Thompson, B.J.↗
DOE OSTI2025

Active learning path-dependent properties using a cloud-based materials acceleration platform

Solid state materials are central to many modern technologies in which a given material may be exposed to a variety of environments. The material properties often vary with the sequence of environments in an irreversible manner, resulting in a quintessential path-dependency in experimental observables. While sequential learning techniques have been effectively deployed for accelerating learning of state properties of materials, they often use a consistent environment path in all experiments. To elevate such techniques for making optimal decisions in experimental investigations of path-dependent properties, we introduce an iterated expected information gain acquisition function that optimizes over entire experimental trajectories. This approach is implemented within a cloud-based Materials Acceleration Platform architecture utilizing an event-driven stateful broker coupled with remote HELAO (Hierarchical Experimental Laboratory Automation and Orchestration) instances and an AI science manager. The platform's efficacy was demonstrated through a case study optimizing multi-step spectro-electrochemical experiments to identify optically stable potential windows in (Co–Ni–Sb)O z metal oxides. The system successfully integrated AI-driven experiment design, remote laboratory automation, and cloud-based data infrastructure, validating the platform's capability for managing complex, adaptive, path-dependent workflows in materials discovery.

Guevarra, Dan [California Institute of Technology ↗