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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 19 records
All sourcesNASA NTRSDOE OSTI
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 OSTI2026

Utilization of Unmanned Aircraft Systems for Environmental Purposes at the Savannah River Site – 26578

Born in the 1950s, the Savannah River Plant was constructed as a plutonium and tritium production plant. As the Cold War era came and went, a change of direction was signaled when the name of the facility changed from Savannah River Plant to Savannah River Site (1989) – the main mission at Savannah River shifted from “production” to “cleanup.” The Department of Energy is responsible for managing the 310 square miles of land that is the Savannah River Site and the cleanup/remediation activities that occur. The Savannah River National Laboratory utilizes unmanned aircraft systems to assist with some of those environmental monitoring and remediation activities. One function of unmanned aircraft systems at the Savannah River National Laboratory is conducting aerial photography and videography. Various infrastructure evaluations have been performed with unmanned aircraft – facility rooftop inspections, water tower lock verifications, earthen dam surveys, etc. An unmanned aircraft system has been used for progress footage of remediation projects – Dunbarton Bay remediation, Saltstone Disposal Unit construction, etc. Thermal cameras on an unmanned aircraft system are used to help identify cracks/leaks in structures from vantage points not readily accessible by personnel. Virtual tours of different waste units are conducted with unmanned aircraft systems for Site groups and federal/state regulators to save costs and travel time. Additionally, advanced remote sensing technologies are used on unmanned aircraft systems at the Savannah River Site. Light Detection and Ranging uses laser pulses to measure distances to the Earth's surface or other targets to create highly detailed topographic maps that accurately portray terrain (e.g., elevation changes, slopes, and contours). Data collection with a Light Detection and Ranging unit mounted on an unmanned aircraft system is quick and efficient – large-area surveys are conducted in shorter time frames. Because Light Detection and Ranging can penetrate through foliage and vegetation to ground level, it is being used in conjunction with a watershed model to study the General Separations Area of the Site to determine stormwater flow volume and direction, monitor stream stability, and forecast river flow behavior. A hyperspectral camera captures a wide spectrum of electromagnetic wavelengths across numerous narrow bands, beyond what the human eye can see. It provides detailed spectral information about the objects or surfaces in an image, which can be used to identify and analyze materials based on their spectral signatures. A hyperspectral camera mounted on an unmanned aircraft system has been used at the Savannah River Site for non-destructive evaluation of concrete and concrete structures. Unmanned aircraft systems at the Savannah River Site are also used for the application of herbicide on identified rooftops. P-Reactor and R-Reactor are entombed nuclear reactors at the Savannah River Site. Unwanted vegetation is often present on these rooftops – over time roots can penetrate seams, cracks, and joints of the general roof and concrete caps, leading to water ingress and deterioration of the structural components. For time and cost efficiencies as well as in the interest of personnel safety, an unmanned aircraft is used to dispense herbicide on rooftop areas where vegetation is noticed to help alleviate the issues/hazards.

Lorier, Troy [Savannah River National Laboratory (↗
DOE OSTI2025

Colorado Alternatively Powered Aircraft Airport Infrastructure Study

Advanced Air Mobility encompasses emerging technologies in propulsion of general aviation and commuter aircraft for the purpose of moving passengers and goods. The State of Colorado has a strong aerospace and aviation legacy, and this research explores the potential energy implications of a transition from traditional aircraft propulsion systems to more-electric, full electric and hydrogen powered aircraft in flight schools, and small community air service utilizing NASA's Regional Air Mobility Model. Effort includes identifying potential energy needs and cost-effective solutions to support those emerging needs analyzing potential benefits on on-site generation and storage to optimize energy systems.Advanced Air Mobility encompasses emerging technologies in propulsion of general aviation and commuter aircraft for the purpose of moving passengers and goods. The State of Colorado has a strong aerospace and aviation legacy, and this research explores the potential energy implications of a transition from traditional aircraft propulsion systems to more-electric, full electric and hydrogen powered aircraft in flight schools, and small community air service utilizing NASA's Regional Air Mobility Model. Effort includes identifying potential energy needs and cost-effective solutions to support those emerging needs analyzing potential benefits on on-site generation and storage to optimize energy systems.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Fleet-Level Fuel Impact of Hybrid-Electric Aircraft in United States

Here, this paper examines the impact of two potential solutions for increasing fuel efficiency and reducing emissions in commercial aviation: hybrid-electric propulsion and the use of drop-in synthetic aviation fuels (SAFs). The authors modeled three representative aircraft employed in the U.S. domestic market: a 70-seat regional turboprop, a 100-seat airliner, and a 180-seat airliner. These aircraft were retrofitted with hybrid-electric propulsion systems that integrate batteries and electric motors to provide additional torque to the propeller or fan. The authors explored various technological scenarios involving different battery specific energies, electric motor specific powers, and other relevant parameters. Flight performance models were used to analyze the range–payload capabilities of these new hybrid-electric aircraft and to compare them with their conventional counterparts. Subsequently, the authors virtually deployed the hybrid-electric aircraft on 2019 U.S. domestic commercial flights to assess the types and lengths of flights that could be serviced by this new fleet. We then compared the resulting fuel consumption, energy use, and emissions with those of a conventional fleet using a combination of jet fuel and SAF.

SAF↗
DOE OSTI2025

Power Electronics and Electric Machines for Advanced Aircraft

Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.

42 ENGINEERING↗
DOE OSTI2026

Improving the Confidence in Retrievals of Vertical Distributions of Cloud Condensation Nuclei Number Concentration from ARM Supported by Aircraft In Situ Observations

Accurate quantification of the vertical distribution of cloud condensation nuclei (CCN) number concentrations is critical for improving our understanding of aerosol–cloud interactions. Ground-based Raman lidars operated by the Atmospheric Radiation Measurement (ARM) program, together with surface CCN measurements, are used to retrieve vertically resolved CCN number concentrations (Retrieved Number concentration of CCN, RNCCN). These retrievals rely on several assumptions, including that aerosol composition is vertically homogeneous. To assess this assumption, we developed and tested a framework to infer the dominant aerosol classes/types at different altitudes. This was done by applying a k-Nearest-Neighbors (kNN) algorithm to lidar ratio and linear depolarization ratio measurements from Raman lidar. We evaluated the framework using aircraft aerosol and CCN measurements from the ARM Holistic Interactions of Shallow Clouds, Aerosols, and Land Ecosystems (HI-SCALE) field campaign. The results show that RNCCN performance degrades as vertical aerosol complexity increases, i.e., RNCCN agrees with the aircraft CCN in vertically homogeneous conditions, but closure decreases in layered aerosol structures. To generalize beyond individual examples, we introduce a metric (heterogeneity index) that quantifies the vertical complexity by assessing the variation of inferred aerosol classes/types. Case-level statistics show a tendency for RNCCN and aircraft differences to increase with this metric. By detecting retrievals that are likely compromised by aerosol vertical heterogeneity, the proposed framework improves the interpretability and effective use of RNCCN used for long-term evaluation of models and aerosol–cloud interactions.

Tian, Jingjing↗
DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗
DOE OSTI2025

Direct Observations of Surface Fluxes and Air‐Sea Exchange Coefficients in Low Winds Using a Small Uncrewed Aircraft System

In the marine boundary layer, the exchange of momentum, heat, and moisture occurs between the atmosphere and ocean. Since it is too dangerous for a crewed aircraft to fly close to the ocean surface to directly obtain these measurements, a sUAS (small Uncrewed Aircraft System) is one of the only viable options. On 24 March 2023 a Black Swift Technologies S0 sUAS was deployed from the NOAA P-3 on a calm clear day off the west coast of Florida. For 23 min at the end of the mission, the sUAS flew 8 straight line legs with an average length of 2.15 km, at roughly 10 m above the ocean surface, with wind speeds between 3.0 and 4.5 m s −1 . For the first time over the open ocean using a sUAS, the 4-Hz wind and thermodynamic data was used to calculate surface momentum flux, sensible heat flux, and latent flux using both direct covariance methods and the bulk aerodynamic formulas. Since all the flux quantities can be found using both direct and indirect methods, we are able to calculate the exchange coefficients of momentum flux (C D ), latent heat flux (C E ), and sensible heat flux (C H ) with results that are generally in good agreement with previous studies over the same wind speed range. This study demonstrates the ability of sUAS to measure air-sea interactions. Future intention is to use sUAS to obtain similar measurements in high wind events such as hurricanes which could better help understand hurricane intensification and improve model physics.

Deloach, Christopher J. [Embry-Riddle Aeronautical↗
DOE OSTI2026

Methodology For Determining The Effective Aircraft Impact Area For Irregularly Shaped Facilities

This report presents a computational methodology for determining the effective aircraft impact area for irregularly shaped facilities, extending the approach in Department of Energy (DOE) Standard 3014 by decomposing “critical areas” into multiple rectangular nodes rather than relying on a single bounding cuboid. This method reduces unnecessary conservatism that can arise when non-critical space is enveloped by a single footprint. The facility’s critical areas are partitioned into nodes of constant height, a baseline aircraft impact trajectory is established, and the facility perspective is rotated to accommodate arbitrary heading angles. For each node, analytic expressions are provided to construct the node-specific effective impact polygon that accounts for skid distance, structural footprint, fly-in (shadow) region driven by building height and descent angle, and wingspan offsets capturing wing-only strikes.

42 ENGINEERING↗
DOE OSTI2026

Aircraft-derived particle fluxes distinguish entrainment zone and decoupled layer nucleation in marine boundary layers

The vertical distribution of freshly nucleated aerosol particles in the marine boundary layer remains poorly constrained, limiting our ability to represent new particle formation in climate models. Here we characterize 3–10 nm particle events, termed small particle events (SPEs), by deriving their vertical turbulent fluxes from aircraft measurements during the Aerosol and Cloud Experiments in the Eastern North Atlantic (ACE-ENA) campaign. To overcome stationarity limitations of traditional eddy covariance methods, we applied continuous wavelet transform analysis to data collected during June–July 2017 and January–February 2018 flights over the Azores. Our flux-based analysis revealed two distinct SPE scenarios with different vertical structures and spatial extents. The first featured nucleation in the entrainment zone, where free tropospheric air entrains into the boundary layer. The second showed nucleation in the decoupled layer, a stratified region between the well-mixed surface layer and cloud-topped upper boundary layer. In both cases, convergence of air masses from different layers diluted preexisting aerosol surface area to very low levels, creating conditions favorable for nucleation and generating strong downward particle fluxes. SPEs occurred in 15 % of flights, challenging prevailing theoretical expectations that new particle formation should rarely occur in marine boundary layers due to high condensation and coagulation sink capacity of sea spray aerosols. Aircraft-derived particle fluxes provide first observational constraints on the vertical location and source strength of likely nucleation regions in the remote marine boundary layer, improving aerosol source representations in climate models and reducing uncertainties in aerosol-cloud interactions.

Rasheeda Satheesh, Ajmal [North Carolina State Uni↗
DOE OSTI2026

CFD-Enhanced Calibration of a Multihole Probe for Small Uncrewed Aircraft Systems

A robust calibration method with a 9-hole probe (9HP) for inertial wind vector measurements from a small uncrewed aircraft system (sUAS) is presented. Calibration accuracy is improved by using computational fluid dynamics (CFD) to estimate corrections, such as those for test section blockage, that are generally applied in wind tunnel testing. A method for estimating experimental bias is presented to account for flow variations over the pressure taps as the 9HP is repositioned in the test section. Installation effects from flow over the airframe and upwash produced by the wings are estimated from CFD simulations of the entire airframe at the expected cruise speed. An initial CFD analysis has demonstrated a quantifiable linear relationship between the measured and actual angle of attack as measured from the relative wind frame. In conclusion, the objective of these additional steps is to increase the accuracy of 9HP calibration.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Measurements of TRACER pre-convective conditions and mesoscale circulations using small unmanned aircraft systems (sUAS)

Improved comprehension of the physical processes governing convective cloud formation and lifecycle are of critical importance for understanding and predicting future climate states. The influence of these clouds on the planetary energy budget, including on precipitation, is significant. Things are particularly complex in coastal regimes, where gradients in aerosol particle properties, localized circulations such as sea breezes, and large population centers are found. To date, numerical models struggle to accurately represent these critical clouds and are therefore challenged to provide a realistic view on the planetary energy budget. Through the proposed research, we deployed two uncrewed aircraft systems (UAS) equipped with a variety of instruments alongside sensors deployed by the US Department of Energy Atmospheric Radiation Measurement (ARM) program for the TRACER (Tracking Aerosol Convection Interactions Experiment) field campaign. The two small UAS platforms consisted of a CU RAAVEN fixed-wing airplane and an OU CopterSonde system, with the copter collecting frequent vertical profiles of thermodynamic and kinematic variables such as temperature, pressure, wind and humidity. At the same time, the fixed-wing captured horizontal gradients of these quantities and aerosol size distribution. These systems were deployed south of the Houston metro area, in an area that is impacted by the Gulf of Mexico sea breeze on a daily basis. These observations offer enhanced and complementary perspectives to those provided by the DOE ARM Mobile Facility (AMF) which is was deployed in southeast Houston, and an ancillary site in a more rural location west of the urban Houston area. Quality-controlled versions of the UAS data were collected and posted on the DOE ARM data archive after the conclusion of the campaign where they are accessible by the research community and general public. The UAS perspective offers revolutionary insight into key spatial and temporal effects that have not been evaluated previously.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

A non-melting additive approach to structural repair of aluminum aircraft fastener holes

The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Aircraft Measurements from a U.S. Western Wildfire Demonstrating Day and Night Differences in the Chemical Composition and Optical Properties of Biomass Burning Aerosols and Their Atmospheric Evolution

The composition and transformations of biomass burning aerosols (BBA) have been measured onboard the NOAA Twin Otter research aircraft during the Fire Influence on Regional to Global Environments and Air Quality field study. Here, we analyze real-time aerosol mass spectrometry measurements across three flights during the afternoon, late afternoon, and night of August 28, 2019, for one midsized wildfire. Analysis of several metrics showed that the aerosol composition and optical properties varied depending on the burning conditions at the fire zone and the time of day the BBA was emitted, with substantial variations in the available sunlight. The total aerosol mass loadings were dominated by organic components with a much smaller contribution from inorganic species. A gradual buildup of organic material was observed during the afternoon as the plume aged, indicating the condensation of photochemically formed low-volatility oxidized organic compounds. Highly hygroscopic ammonium nitrate was the main inorganic component, suggesting potential water content in BBA particles and the likelihood of their aqueous-phase reactivity. Depletions of particle-phase NO 3 – and Cl – relative to carbon monoxide were observed in the late afternoon and nighttime plumes, respectively, aligning with known gas-particle partitioning thermodynamics and the heterogeneous chemistry of dissolved nitrate and chloride. The wavelength-dependent light absorption by aerosol species was higher for the plume sampled at night and showed no significant changes with plume age, despite observed trends in composition and mass downwind. These differences in particle composition and optical properties demonstrate that the processes involved in BBA aging are not uniform for the same wildfire over the course of the day and depend highly on when the BBA was emitted, as well as the burning phase at the emissions source.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

How Representative Are Uncrewed Aircraft System Measurements of the Convective Boundary Layer?

Abstract Uncrewed aircraft systems (UAS) demonstrate significant potential for filling data gaps in the atmospheric boundary layer. However, the extent to which UAS observations—typically vertical profiles taken over 15 min—are representative of the boundary layer as a whole remains poorly characterized. Using large eddy simulations (LES) of the daytime convective boundary layer (CBL), we quantify random errors in UAS measurements that occur due to insufficient statistical convergence of the time average to the true ensemble mean. Random errors in first‐order moments increase as the CBL becomes increasingly unstable, and are largest near the surface for most quantities. Errors are on the order of 2–6 m for wind speed, 15–60 for wind direction, 0.2–3 K for potential temperature, and 0.1–1 g for specific humidity, with errors in turbulent fluxes on the order of 50%–100%. Sampling strategies that mitigate random errors are discussed in light of our results.

Greene, Brian R. [Now at Verisk Extreme Event Solu↗
DOE OSTI2025

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗
DOE OSTI2026

A Hierarchical Optimization Method for Electric Vertical Takeoff and Landing Aircraft Network Design

Electric vertical takeoff and landing aircraft (eVTOLs) are expected to serve urban air mobility in a station-to-station configuration, which makes the optimal network design of eVTOL stations a critical question to explore. Existing approaches often face limitations, such as the inability to interact station locations with demand or difficulty in finding the optimal solution for large study regions. Here, this paper first proposes a mathematical model to generate optimal eVTOL station locations while considering associated potential eVTOL demand, and then proposes a heuristic algorithm, Hierarchical Optimization MEthod (HOME), to efficiently solve the model. With a case study of Southern California, HOME was compared to 1) directly solving the original integer linear programming-based network design problem, and 2) employing the widely used genetic algorithm. Results suggest that HOME can find optimal solutions with limited computational resources. The proposed framework powered by HOME provides a computationally efficient way to support urban air mobility planning.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Unmanned Aircraft Systems (UAS) and Light Detection and Ranging (LiDAR)/Camera Technologies to Detect Avian Events and Other Environmental Measures at Utility- Scale Power Plants (Final Report)

The goal of this project was to develop and validate two complementary, cost-effective remote sensing technologies to monitor avian fatalities at utility-scale solar facilities: fixed platform (Animal Activity Monitoring-AAM) and aerial-based (Uncrewed Aircraft Systems-UAS). This project used these features with machine learning to automate the detection of avian carcasses and nests at solar facilities.

14 SOLAR ENERGY↗