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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 1,747 records · Page 97

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DOE OSTI2014

Full-field X-ray reflection microscopy of epitaxial thin-films

Novel X-ray imaging of structural domains in a ferroelectric epitaxial thin film using diffraction contrast is presented. The full-field hard X-ray microscope uses the surface scattering signal, in a reflectivity or diffraction experiment, to spatially resolve the local structure with 70 nm lateral spatial resolution and sub-nanometer height sensitivity. Sub-second X-ray exposures can be used to acquire a 14 µm × 14 µm image with an effective pixel size of 20 nm on the sample. The optical configuration and various engineering considerations that are necessary to achieve optimal imaging resolution and contrast in this type of microscopy are discussed.

interfaces and thin films↗

DOE OSTI2026

AMAROK: A Radio Frequency Development Platform for High-Power, Full-Scale Positive Ion Sources for DIII-D Neutral Beam Injectors

Next-generation neutral beam injection (NBI) systems demand RF ion sources capable of efficiently coupling >120 kW at 2–4-MHz frequencies, yet existing designs face voltage standoff and impedance-matching challenges. To address this, the advanced multicoil antenna for RF operations at kilowatts (AMAROK) was developed as a high-power RF inductively coupled plasma (ICP) source delivering up to 200 kW in the 2–4-MHz range via four phase-controlled generators for flexible power sharing. Two antenna designs—a single-strap multiturn (MT) and a multistrap single-turn (ST) design—were evaluated to optimize resonance, impedance matching, and power coupling across plasma loads. Here, a semi-analytical self-resonant frequency (SRF) model, validated experimentally, predicts resonance trends for arbitrary turn counts and tubing diameters, enabling rapid antenna optimization. Strap-to-strap mutual inductance in the ST configuration showed strong spatial dependence, guiding generator operation and total load inductance. These insights informed a custom π -topology matching network, achieving stable impedance matching over a wide range of plasma-driven loads. Collectively, these results position AMAROK as a versatile testbed for advancing high-power RF source technology in fusion NBI applications.

DIII-D↗

DOE OSTI2016

Probabilistic distributions of pinhole defects in atomic layer deposited films on polymeric substrates

Pinhole defects in atomic layer deposition (ALD) coatings were measured in an area of 30 cm{sup 2} in an ALD reactor, and these defects were represented by a probabilistic cluster model instead of a single defect density value with number of defects over area. With the probabilistic cluster model, the pinhole defects were simulated over a manufacturing scale surface area of ∼1 m{sup 2}. Large-area pinhole defect simulations were used to develop an improved and enhanced design method for ALD-based devices. A flexible thermal ground plane (FTGP) device requiring ALD hermetic coatings was used as an example. Using a single defect density value, it was determined that for an application with operation temperatures higher than 60 °C, the FTGP device would not be possible. The new probabilistic cluster model shows that up to 40.3% of the FTGP would be acceptable. With this new approach the manufacturing yield of ALD-enabled or other thin film based devices with different design configurations can be determined. It is important to guide process optimization and control and design for manufacturability.

42 ENGINEERING↗

DOE OSTI2025

On Rate-Limiting Mechanisms in NMC Cathodes: The Interplay of Low and High Current Constraints

In this study, we investigate the rate performance limits in LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes for lithium-ion batteries, focusing on how cathode thickness, porosity, and threshold voltage impact discharge capacity. By conducting galvanostatic discharge experiments across a wide range of current densities using cathodes of varying thicknesses and porosities, we identify two distinct rate-limiting mechanisms: ionic liquid-diffusion and Ohmic/charge-transfer limitations. Our findings show that thick, dense cathodes are primarily limited by lithium diffusion in the electrolyte, while thinner and more porous cathodes are dominated by Ohmic/charge-transfer limitations, particularly at higher lower cutoff voltages. Crucially, these results allow us to identify the rate-limiting mechanisms in different cathode configurations, offering clear insights into how cathode design can be optimized for improved performance. Understanding these mechanisms is essential for designing next-generation batteries with enhanced rate performance, which is critical for applications such as electric vehicles and renewable energy storage systems.

Brischetto, Martin (ORCID:0000000339865813)↗

DOE OSTI2017

Volumetric Additive Manufacturing of Polymer Structures by Holographically Projected Light Fields

As additive manufacturing technologies proliferate and mature, overcoming some of their process limitations becomes increasingly important for the continued expansion of practical applications. Two such limitations that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality and challenges fabricating span, cantilever, and overhang elements). Moving beyond point-by-point and layer-by-layer approaches, the ability to generate a complex 3D volume as a unit operation has the potential to overcome these limitations. Since holography has been extensively studied as a means for storage and retrieval of 3D geometrical information, this dissertation explores the use of holographically-shaped light fields for producing three-dimensional structures in a “volume at once” approach. Leveraging advances in spatial light modulator (SLM) technology, phase-controlled light fields are projected into photopolymer resin to cure a desired geometry. By overlapping multiple sub-regions of a single light field within the target volume, the successful fabrication of non-periodic complex 3D geometries is demonstrated by single exposures on timescales of seconds. This dissertation presents a complete prototype platform that makes this approach possible, comprising a suitable hardware configuration along with the computational algorithms necessary to calculate and optimize the required optical fields. A study of the photopolymerization kinetics is also carried out, to determine the boundaries of usable process parameters such as resin absorbance and available light intensity. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100 mW) may be used to produce full 3D structures from 1-10 second exposures, with volume build rates exceeding 100 cm3/hr, without layering and with no need for a substrate or support material.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Improve Replication of In-service Mechanical Environments

Structural dynamic testing is a common method for determining if the design of a component of a system will mechanically fail when deployed into its field environment. To satisfy the test's goal, the mechanical stresses must be replicated. Structural dynamic testing is commonly executed on a shaker table or a shock apparatus such as a drop table or a resonant plate. These apparatus impart a force or load on the component through a test fixture that connects the unit under test to the apparatus. Because the test fixture is directly connected to the unit under test, the fixture modifies the structural dynamics of the system, thus varying the locations and relative levels of stress on the unit under test. This may lead to a false positive or negative indication if the unit under test will fail in its field environment depending on the environment and the test fixture. This body of research utilizes topology optimization using the Plato software to design a test fixture that attaches to the unit under test that matches the dynamic impedance of the next level of assembly. The optimization's objective function is the difference between the field configuration and the laboratory configuration's frequency response functions. It was found that this objective function had many local minima and posed difficulties in converging to an acceptable solution. A case study is presented that uses this objective function and although the results are not perfect, they are quantifiably better than the current method of using a sufficiently stiff fixture.

42 ENGINEERING↗

DOE OSTI2021

Development of Efficient Process for Manufacturing of Thermoplastic Composites with Tailored Properties (CRADA 511)

This is a collaborative effort between Battelle Memorial Institute as manager and operator of Pacific Northwest National Laboratory (PNNL) and ESI North America Inc. (“ESI” or “Participant”) to apply computation and data analytics to the challenge of light weighting with a focus on the battery enclosures of electric vehicles (EVs). EVs use heavy batteries to increase range and power. A complex-shaped battery enclosure is required to meet a host of challenging performance requirements. The ability to virtually develop composite parts such as battery enclosure with tailored properties to meet required performance will be highly valuable to the automotive industry. However, efficient simulation of composite-manufacturing processes remains a challenging issue since simulation involves multiscale models in space and time, highly non-linear and anisotropic behavior, strongly coupled multi-physics, and complex geometries. This work will advance the state of the art by reducing the computational burden of composite optimization by using simulation data from a limited number of configurations off-line and then developing a reduced order model (ROM) using data analytics and machine learning (ML). Develop a data driven approach to link features of the material and manufacturing processes to the mechanical properties of thermoplastic composite parts.

42 ENGINEERING↗

DOE OSTI2026

Advancing In-Situ Plasma Processing for SRF Cavities at Fermilab

This talk presents Fermilab’s experience with plasma processing applied to both elliptical and low-beta superconducting RF cavities. The development and implementation of the technique are compared across different geometries, with particular emphasis on constraints imposed by cryomodule assembly configurations. The talk also reports on systematic studies aimed at optimizing the processing recipe, including the exploration of various inert gas mixtures and oxygen concentrations. These results aim at providing guidance for tailoring plasma processing conditions to different cavity types and advancing plasma processing applicability in operational cryomodules.

Giaccone, Bianca [Fermilab] (ORCID:000000027275846↗

DOE OSTI2026

Advancing In-Situ Plasma Processing for SRF Cavities at Fermilab

Giaccone, Bianca [Fermilab] (ORCID:000000027275846↗

DOE OSTI2025

Mapping Spiking Neural Networks to Heterogeneous Crossbar Architectures using Integer Linear Programming

Advances in novel hardware devices and architectures allow Spiking Neural Network (SNN) evaluation using ultra-low power, mixed-signal, memristor crossbar arrays. As individual network sizes quickly scale beyond the dimensional capabilities of single crossbars, networks must be mapped onto multiple crossbars. Crossbar sizes within modern Memristor Crossbar Architectures (MCAs) are determined predominately not by device technology but by network topology; more, smaller crossbars consume less area thanks to the high structural sparsity found in larger, brain-inspired SNNs. Motivated by continuing increases in SNN sparsity due to improvements in training methods, we propose utilizing heterogeneous crossbar sizes to further reduce area consumption. This approach was previously unachievable as prior compiler studies only explored solutions targeting homogeneous MCAs. Our work improves on the state-of-the-art by providing Integer Linear Programming (ILP) formulations supporting arbitrarily heterogeneous architectures. By modeling axonal interactions between neurons, our methods produce better mappings while removing inhibitive a priori knowledge requirements. We first show a 16.7-27.6% reduction in area consumption for square-crossbar homogeneous architectures. Then, we demonstrate 66.9-72.7% further reduction when using a reasonable configuration of heterogeneous crossbar dimensions. Next, we present a new optimization formulation capable of minimizing the number of inter-crossbar routes. When applied to solutions already near-optimal in area, an 11.9-26.4% routing reduction is observed without impacting area consumption. Finally, we present a profile-guided optimization capable of minimizing the number of runtime spikes between crossbars. Compared to the best-area-then-route optimized solutions, we observe a further 0.5-14.8% inter-crossbar spike reduction while requiring 1–3 orders of magnitude less solver time.

Pohl, Devin [ORNL] (ORCID:0009000040149027)↗

NASA NTRS1974

Preliminary performance estimates of an oblique, all-wing, remotely piloted vehicle for air-to-air combat

A computerized aircraft synthesis program has been used to assess the effects of various vehicle and mission parameters on the performance of an oblique, all-wing, remotely piloted vehicle (RPV) for the highly maneuverable, air-to-air combat role. The study mission consists of an outbound cruise, an acceleration phase, a series of subsonic and supersonic turns, and a return cruise. The results are presented in terms of both the required vehicle weight to accomplish this mission and the combat effectiveness as measured by turning and acceleration capability. This report describes the synthesis program, the mission, the vehicle, and results from sensitivity studies. An optimization process has been used to establish the nominal RPV configuration of the oblique, all-wing concept for the specified mission. In comparison to a previously studied conventional wing-body canard design for the same mission, this oblique, all-wing nominal vehicle is lighter in weight and has higher performance.

Nelms, W. P., Jr.↗

NASA NTRS1983

Mars Geoscience Orbiter and Lunar Geoscience Orbiter

The feasibility of using the AE/DE Earth orbiting spacecraft design for the LGO and/or MGO missions was determined. Configurations were developed and subsystems analysis was carried out to optimize the suitability of the spacecraft to the missions. The primary conclusion is that the basic AE/DE spacecraft can readily be applied to the LGO mission with relatively minor, low risk modifications. The MGO mission poses a somewhat more complex problem, primarily due to the overall maneuvering hydrazine budget and power requirements of the sensors and their desired duty cycle. These considerations dictate a modification (scaling up) of the structure to support mission requirements.

Fuldner, W. V.↗

NASA NTRS1984

Structural design of a vertical antenna boresight 18.3 by 18.3-m planar near-field antenna measurement system

A large very precise near-field planar scanner was proposed for NASA Lewis Research Center. This scanner would permit near-field measurements over a horizontal scan plane measuring 18.3 m by 18.3 m. Large aperture antennas mounted with antenna boresight vertical could be tested up to 60 GHz. When such a large near field scanner is used for pattern testing, the antenna or antenna system under test does not have to be moved. Hence, such antennas and antenna systems can be positioned and supported to simulate configuration in zero g. Thus, very large and heavy machinery that would be needed to accurately move the antennas are avoided. A preliminary investigation was undertaken to address the mechanical design of such a challenging near-field antenna scanner. The configuration, structural design and results of a parametric NASTRAN structural optimization analysis are contained. Further, the resulting design was dynamically analyzed in order to provide resonant frequency information to the scanner mechanical drive system designers. If other large near field scanners of comparable dimensions are to be constructed, the information can be used for design optimization of these also.

Sharp, G. R.↗

NASA NTRS1987

Model-based analysis of control/display interaction in the hover task

The effect of Control/Display interaction in the hover task is analyzed using an optimal control approach to modeling pilot control behavior. The control/display configurations considered are those previously evaluated in a flight research program. The experimental data-base is reviewed and the procedure for modeling the task and the displayed information is presented in detail. All model-based results, time-domain as well as frequency-domain, are found to correlate extremely well with the subjective pilot ratings and comments. Time-domain measures consist of root mean-square errors and control inputs, attention allocation to displayed quantities, and magnitudes of task objective function. Frequency-domain measures include bandwidth, stability margins, and pilot phase compensation. Results are also shown to agree with previous findings on task interference in multi-axis tasks.

Schmidt, David K.↗

NASA NTRS1988

A feedback linearization approach to spacecraft control using momentum exchange devices

Recent developments in the area of nonlinear control theory have shown how coordiante changes in the state and input spaces can be used with nonlinear feedback to transform certain nonlinear ordinary differential equations into equivalent linear equations. These feedback linearization techniques are applied to resolve two problems arising in the control of spacecraft equipped with control moment gyroscopes (CMGs). The first application involves the computation of rate commands for the gimbals that rotate the individual gyroscopes to produce commanded torques on the spacecraft. The second application is to the long-term management of stored momentum in the system of control moment gyroscopes using environmental torques acting on the vehicle. An approach to distributing control effort among a group of redundant actuators is described that uses feedback linearization techniques to parameterize sets of controls which influence a specified subsystem in a desired way. The approach is adapted for use in spacecraft control with double-gimballed gyroscopes to produce an algorithm that avoids problematic gimbal configurations by approximating sets of gimbal rates that drive CMG rotors into desirable configurations. The momentum management problem is stated as a trajectory optimization problem with a nonlinear dynamical constraint. Feedback linearization and collocation are used to transform this problem into an unconstrainted nonlinear program. The approach to trajectory optimization is fast and robust. A number of examples are presented showing applications to the proposed NASA space station.

Dzielski, John Edward↗

NASA NTRS1989

Space Shuttle 2 Advanced Space Transportation System. Volume 1: Executive Summary

An investigation into the feasibility of establishing a second generation space transportation system is summarized. Incorporating successful systems from the Space Shuttle and technological advances made since its conception, the second generation shuttle was designed to be a lower-cost, reliable system which would guarantee access to space well into the next century. A fully reusable, all-liquid propellant booster/orbiter combination using parallel burn was selected as the base configuration. Vehicle characteristics were determined from NASA ground rules and optimization evaluations. The launch profile was constructed from particulars of the vehicle design and known orbital requirements. A stability and control analysis was performed for the landing phase of the orbiter's flight. Finally, a preliminary safety analysis was performed to indicate possible failure modes and consequences.

Adinaro, James N.↗

NASA NTRS1993

More Uses For Configuration Control Of Robots

Two papers present theoretical studies of older and newer uses for configuration control. Configuration control described in "Increasing the Dexterity of Redundant Robots" (NPO-17801) and "Redundant Robot Can Avoid Obstacles" (NPO-17852). One paper "Configuration Control of 7 DOF Arms" reviews these concepts, then applies them to commercial robotic arm having seven revolute joints corresponding to those of human arm. Other paper "New Goals for Redundancy Resolution Using Configuration Control" addresses use of redundant degrees of freedom to optimize dynamical instead of kinematical aspects of performance.

Seraji, Homayoun↗

NASA NTRS1991

Space transfer vehicle concepts and requirements, volume 2, book 1

The objective of the systems engineering task was to develop and implement an approach that would generate the required study products as defined by program directives. This product list included a set of system and subsystem requirements, a complete set of optimized trade studies and analyses resulting in a recommended system configuration, and the definition of an integrated system/technology and advanced development growth path. A primary ingredient in the approach was the TQM philosophy stressing job quality from the inception. Included throughout the Systems Engineering, Programmatics, Concepts, Flight Design, and Technology sections are data supporting the original objectives as well as supplemental information resulting from program activities. The primary result of the analyses and studies was the recommendation of a single propulsion stage Lunar Transportation System (LTS) configuration that supports several different operations scenarios with minor element changes. This concept has the potential to support two additional scenarios with complex element changes. The space based LTS concept consists of three primary configurations--Piloted, Reusable Cargo, and Expendable Cargo.

Source record↗