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At least 19 records

Recent progress in atomic-scale controlled plasma processing

Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.

Ishikawa, Kenji [Nagoya Univ. (Japan)] (ORCID:0000↗

Measurements of unsteady pressure and structural response for an elastic supercritical wing

Results are presented which define unsteady flow conditions associated with the high-dynamic structural response of a high-aspect-ratio, elastic, supercritical wing at transonic speeds. The wing was tested in the Langley Transonic Dynamics Tunnel with a heavy gas test medium. The supercritical wing, designed for a cruise lift coefficient of 0.53 at a Mach number of 0.80, experienced the high-dynamic structural response from Mach 0.90 to 0.94 with the maximum response occurring at about Mach 0.92. At the maximum response conditions of the wing, the forcing function appears to be the oscillatory chordwise movement of strong shocks located on the upper and lower surfaces of the wing in conjunction with the flow separation on the lower surface of the wing in the trailing-edge cove region.

Eckstrom, Clinton V.↗

Adaptive aeroelastic composite wings - Control and optimization issues

High-performance aircraft are adaptive machines composed of internal structural skeletons to which are attached control surfaces operated by hydraulic muscles to allow them to maneuver. The flight crew, avionic sensors and systems function as the brain and nervous system to adapt the machine to changing flight conditions, such as take-off, cruise and landing. The development of new materials that can expand or contract on command or change stiffness on demand will blur the now distinct boundaries between the structure, actuators and the control system. This paper discusses the use of imbedded active piezoelectric materials to change the aeroelastic stiffness of a lifting surface to allow this surface to control the aircraft. Expressions are developed for the piezoelectric material effectiveness when these active materials are combined with advanced composite structural materials for a swept, high-aspect-ratio wing. The interaction between advanced composite material properties and piezoelectric electromechanical properties is examined. The importance of choosing the proper active control laws is also illustrated.

Weisshaar, Terrence A.↗

The use of the Regier number in the structural design with flutter constraints

This preliminary investigation introduces the use of the Regier number as a flutter constraint criterion for aeroelastic structural optimization. Artificial neural network approximations are used to approximate the flutter criterion requirements as a function of the design Mach number and the parametric variables defining the aspect ratio, center of gravity, taper ratio, mass ratio, and pitch inertia of the wing. The presented approximations are simple enough to be used in the preliminary design stage without a well defined structural model. An example problem for a low-speed, high-aspect-ratio, light-aircraft wing is presented. The example problem is analyzed for the flutter Mach number using doublet lattice aerodynamics and the PK solution method. The use of the Regier number constraint criterion to optimize the example problem for minimum structural mass while maintaining a constant flutter Mach number is demonstrated.

Dunn, H. J.↗

Microfabricated structures with electrical isolation and interconnections

The invention is directed to a microfabricated device. The device includes a substrate that is etched to define mechanical structures at least some of which are anchored laterally to the remainder of the substrate. Electrical isolation at points where mechanical structures are attached to the substrate is provided by filled isolation trenches. Filled trenches may also be used to electrically isolate structure elements from each other at points where mechanical attachment of structure elements is desired. The performance of microelectromechanical devices is improved by 1) having a high-aspect-ratio between vertical and lateral dimensions of the mechanical elements, 2) integrating electronics on the same substrate as the mechanical elements, 3) good electrical isolation among mechanical elements and circuits except where electrical interconnection is desired.

Clark, William A.↗

Technology for future air transports

The requirements and opportunities for technological development in transport aircraft of the next generation are reviewed, focusing primarily on conventional, subsonic aircraft. Advances in computational aerodynamics and computer-aided design and manufacturing (in numerically controlled processes) are noted as well as improved wind tunnel testing and drag reduction techniques. Advances in aeroelasticity prediction have made it possible to use flexible, high-aspect-ratio wings without large weight penalties. Weight reduction may be achieved by the use of composite aircraft structures and superplastic forming combined with diffusion bonding, however composites require improvement in manufacturing techniques and mechanical properties in order to gain general acceptance. Propulsion systems can be improved in engine fuel efficiency, control, durability, environmental compatibility (exhaust and noise emissions), and fuel specifications. In avionics, due to the growth of low-cost, miniaturized packages, opportunities exist in the fields of digital controls, navigation, guidance and communication. Applications of new technologies to various aspects of flight safety are also outlined.

Klineberg, J. M.↗

Application of an optimized winglet configuration to an advanced commercial transport

The design is presented of an aircraft which employs an integrated wing and winglet lift system. Comparison was made with a conventional baseline configuration employing a high-aspect-ratio supercritical wing. An optimized wing-winglet combination was selected from four proposed configurations for which aerodynamic, structural, and weight characteristics were evaluated. Each candidate wing-winglet configuration was constrained to the same induced drag coefficient as the baseline aircraft. The selected wing-winglet configuration was resized for a specific medium-range mission requirement, and operating costs were estimated for a typical mission. Study results indicated that the wing-winglet aircraft was lighter and could complete the specified mission at less cost than the conventional wing aircraft. These indications were sensitive to the impact of flutter characteristics and, to a lesser extent, to the performance of the high-lift system. Further study in these areas is recommended to reduce uncertainty in future development.

Shollenberger, C. A.↗

Correlation of Structural Analysis and Test Results for the McDonnell Douglas Stitched/RFI All-Composite Wing Stub Box

The analytical and experimental results of an all-composite wing stub box are presented in this report. The wing stub box, which is representative of an inboard portion of a commercial transport high-aspect-ratio wing, was fabricated from stitched graphite-epoxy material with a Resin Film Infusion manufacturing process. The wing stub box was designed and constructed by the McDonnell Douglas Aerospace Company as part of the NASA Advanced Composites Technology program. The test article contained metallic load-introduction structures on the inboard and outboard ends of the graphite-epoxy wing stub box. The root end of the inboard load introduction structure was attached to a vertical reaction structure, and an upward load was applied to the outermost tip of the outboard load introduction structure to induce bending of the wing stub box. A finite element model was created in which the center portion of the wing-stub-box upper cover panel was modeled with a refined mesh. The refined mesh was required to represent properly the geometrically nonlinear structural behavior of the upper cover panel and to predict accurately the strains in the stringer webs of the stiffened upper cover panel. The analytical and experimental results for deflections and strains are in good agreement.

Wang, John T.↗

Coupled bending-bending-torsion flutter of a mistuned cascade with nonuniform blades

A set of aeroelastic equations describing the motion of an arbitrarily mistuned cascade with flexible, pretwisted, nonuniform blades is developed using an extended Hamilton's principle. The derivation of the equations has its basis in the geometric nonlinear theory of elasticity in which the elongations and shears are negligible compared to unity. A general expression for foreshortening of a blade is derived and is explicitly used in the formulation. The blade aerodynamic loading in the subsonic and supersonic flow regimes is obtained from two-dimensional, unsteady, cascade theories. The aerodynamic, inertial and structural coupling between the bending (in two planes) and torsional motions of the blade is included. The equations are used to investigate the aeroelastic stability and to quantify the effect of frequency mistuning on flutter in turbofans. Results indicate that a moderate amount of intentional mistuning has enough potential to alleviate flutter problems in unshrouded, high-aspect-ratio turbofans.

Kaza, K. R. V.↗

Lifting-line theory of oblique wings in transonic flows

Three-dimensional corrections to the nonlinear mixed flow admitted by a high-aspect-ratio swept wing of practical interest are analyzed by solving a perturbation problem and matching its solution to that of an outer flow. The latter is identified with a linear solution involving a lifting line, but the centerline of the planform is not required to be straight and unyawed. The existence of a similarity in the three-dimensional flow structure for a certain oblique-wing geometry is demonstrated, along with a solution to the reduced problem in a high-subcritical case.

Cheng, H. K.↗

Fan Flutter Analysis Capability Enhanced

The trend in the design of advanced transonic fans for aircraft engines has been toward the use of complex high-aspect-ratio blade geometries with a larger number of blades and higher loading. In addition, integrally bladed disks or blisks are being considered in fan designs for their potential to reduce manufacturing costs, weight, and complexity by eliminating attachments. With such design trends, there is an increased possibility within the operating region of part-speed stall flutter (self-excited vibrations) that is exacerbated by the reduced structural damping of blisk fans. To verify the aeroelastic soundness of the design, the NASA Glenn Research Center is developing and validating an accurate aeroelastic prediction and analysis capability. Recently, this capability was enhanced significantly as described here.

Bakhle, Milind A.↗

Elastic deformation effects on aerodynamic characteristics for a high-aspect-ratio supercritical-wing model

The results of an investigation of the deformations of a high-aspect-ratio, force/pressure, supercritical-wing model during wind tunnel tests and the effects these deformations have on the wing aerodynamics are presented. A finite element model of the wing was developed, and then, for conditions corresponding to wind tunnel test points, experimental aerodynamic loads and theoretical aerodynamic loads were applied to the finite element model. Comparisons were made between the results of these load conditions for changes in structural deflections and for changes in aerodynamic characteristics. The results show that the deformations are quite small and that the pressure data are not significantly affected by model deformation.

Watson, J. J.↗

Examples of X-Ray Characterization Techniques in Energy Storage Research

Lithium-ion batteries have revolutionized the portable electronics and transportation sectors. Their performance is often critically dependent on the crystal structures of the anode and cathode electrode materials, which must enable the transport and reversible storage of lithium ions into and out of the lattice. Because lithium is a low-Z element, characterization of materials for lithium-ion batteries can be particularly challenging. Regardless, X-ray techniques enable analysis of material structures to better understand how battery materials perform and degrade, particularly when combined with other materials characterization and electrochemical characterization techniques. While X-ray techniques are most often used in battery research for phase identification of crystal structures, X-ray characterization techniques are also used for a wide variety of other purposes. I will discuss several examples from my research with various collaborators on several projects that highlight the impact that X-ray characterization techniques can have on battery research. The first example will focus on low-temperature microwave-assisted solvothermal synthesis of vanadium-doped LiFePO4 cathode materials for lithium-ion batteries. (1,2) Through a combination of electrochemical and materials characterization, we determined that low temperature synthesis resulted in metastable phases that enabled incorporation of higher dopant levels than resulting from high-temperature synthesis of thermodynamically stable phases. Rietveld refinement of X-ray diffraction data enabled understanding of how lattice parameters changed with doping levels and synthesis temperature. X-ray absorption near edge spectroscopy enabled understanding of the vanadium and iron oxidation states to confirm how vacancies in the structure caused by doping were charge compensated. This was important to understand because the literature suggests doping can improve LiFePO4 electrical conductivity, which improves battery charge and discharge rates. The second example will focus on understanding residual strain in lithium metal anodes. Lithium-ion batteries typically use graphite anodes, but the charge-storage capacity can be theoretically improved ~10x by using lithium metal as the anode material instead. However, lithium anodes suffer from growth of high-aspect-ratio features, such as dendrites, that can pierce nanoporous polymer separators and lead to short circuits and fires. External pressure is commonly applied to cells to enable better morphological control. We hypothesized that applied pressure may promote strain and possibly work hardening during electrochemical cycling, which motivated us to look for evidence of residual strain in lithium metal cycled under applied pressure using X-ray diffraction and sin2(..psi..) analysis. We found that lithium electrodeposited under high pressure exhibited in-plane compressive strain and that that lithium electrodeposited under low pressure did not. (3) The residual strain that accompanies electrodeposition under high pressure may lead to work hardening, which may explain how a soft metal like lithium can puncture separators and why higher pressure does not always decrease short circuits. (4-6) References: 1) Harrison, K. L.; Manthiram, A. Microwave-Assisted Solvothermal Synthesis and Characterization of Metastable LiFe1- x (VO) x PO4 Cathodes. Inorganic chemistry 2011, 50(8), 3613-3620. 2) Harrison, K. L.; Bridges, C. A.; Paranthaman, M. P.; Segre, C. U.; Katsoudas, J.; Maroni, V. A.; Idrobo, J. C.; Goodenough, J. B.; Manthiram, A. Temperature Dependence of Aliovalent-Vanadium Doping in LiFePO4 Cathodes. Chemistry of Materials 2013, 25(5), 768-781. 3) Rodriguez, M. A.; Harrison, K. L.; Goriparti, S.; Griego, J. J.; Boyce, B. L.; Perdue, B. R. Use of a Be-Dome Holder for Texture and Strain Characterization of Li Metal Thin Films via Sin2 (..psi..) Methodology. Powder Diffraction 2020, 35(2), 89-97. 4) Jungjohann, K. L.; Gannon, R. N.; Goriparti, S.; Randolph, S. J.; Merrill, L. C.; Johnson, D. C.; Zavadil, K. R.; Harris, S. J.; Harrison, K. L. Cryogenic Laser Ablation Reveals Short-Circuit Mechanism in Lithium Metal Batteries. ACS Energy Letters 2021, 6(6), 2138-2144. 5) Harrison, K. L.; Merrill, L. C.; Long, D. M.; Randolph, S. J.; Goriparti, S.; Christian, J.; Warren, B.; Roberts, S. A.; Harris, S. J.; Perry, D. L. Cryogenic Electron Microscopy Reveals That Applied Pressure Promotes Short Circuits in Li Batteries. Iscience 2021, 24(12). 6) Harrison, K. L.; Goriparti, S.; Merrill, L. C.; Long, D. M.; Warren, B.; Roberts, S. A.; Perdue, B. R.; Casias, Z.; Cuillier, P.; Boyce, B. L. Effects of Applied Interfacial Pressure on Li-Metal Cycling Performance and Morphology in 4 M LiFSI in DME. ACS Applied Materials & Interfaces 2021, 13(27), 31668-31679.

batteries↗

Preliminary design of composite wings for buckling, strength and displacement constraints

An unstiffened panel buckling constraint for balanced, symmetric laminated composites is included on the global design level in a mathematical programming structural optimization procedure for designing wing structures. Constraints are introduced by penalty functions, and Newton's method based on approximate second derivatives of the penalty terms is used as the search algorithm to obtain minimum-mass designs. Constraint approximations used during the optimization process contribute to the computational efficiency of the procedure. A criterion is developed that identifies the appropriate conservative form of the constraint approximations that are used with the optimization procedure. Minimum-mass design results are obtained for a multispar high-aspect-ratio wing subjected to material strength, minimum-gage, displacement, panel buckling and twist constraints. The material systems considered for the examples are all graphite-epoxy, graphite-epoxy with boron-epoxy spar caps, and all aluminum. The composite material designs are shown to have an advantage over the aluminum designs since they can often satisfy additional constraints with only small mass increases.

Starnes, J. H., Jr.↗

A study of high-altitude manned research aircraft employing strut-braced wings of high-aspect-ratio

The effect of increased wing aspect ratio of subsonic aircraft on configurations with and without strut bracing. Results indicate that an optimum cantilever configuration, with a wing aspect ratio of approximately 26, has a 19% improvement in cruise range when compared to a baseline concept with a wing aspect ratio of approximately 10. An optimum strut braced configuration, with a wing aspect ratio of approximately 28, has a 31% improvment in cruise range when compared to the same baseline concept. This improvement is mainly due to the estimated reduction in wing weight resulting from use of lifting struts. All configurations assume the same mission payload and fuel. The drag characteristics of the wings are enhanced with the use of laminar flow airfoils. A method for determining the extent of attainable natural laminar flow, and methods for preliminary structural design and for aerodynamic analysis of wings lifting struts are presented.

Smith, P. M.↗

Configuration design studies and wind tunnel tests of an energy efficient transport with a high-aspect-ratio supercritical wing

The results of design studies and wind tunnel tests of high aspect ratio supercritical wings suitable for a medium range, narrow body transport aircraft flying near M=0.80 were presented. The basic characteristics of the wing design were derived from system studies of advanced transport aircraft where detailed structural and aerodynamic tradeoffs were used to determine the most optimum design from the standpoint of fuel usage and direct operating cost. These basic characteristics included wing area, aspect ratio, average thickness, and sweep. The detailed wing design was accomplished through application of previous test results and advanced computational transonic flow procedures. In addition to the basic wing/body development, considerable attention was directed to nacelle/plyon location effects, horizontal tail effects, and boundary layer transition effects. Results of these tests showed that the basic cruise performance objectives were met or exceeded.

Henne, P. A.↗

Unstructured viscous grid generation by advancing-front method

A new method of generating unstructured triangular/tetrahedral grids with high-aspect-ratio cells is proposed. The method is based on new grid-marching strategy referred to as 'advancing-layers' for construction of highly stretched cells in the boundary layer and the conventional advancing-front technique for generation of regular, equilateral cells in the inviscid-flow region. Unlike the existing semi-structured viscous grid generation techniques, the new procedure relies on a totally unstructured advancing-front grid strategy resulting in a substantially enhanced grid flexibility and efficiency. The method is conceptually simple but powerful, capable of producing high quality viscous grids for complex configurations with ease. A number of two-dimensional, triangular grids are presented to demonstrate the methodology. The basic elements of the method, however, have been primarily designed with three-dimensional problems in mind, making it extendible for tetrahedral, viscous grid generation.

Pirzadeh, Shahyar↗

Unstructured viscous grid generation by advancing-layers method

A new method of generating unstructured triangular/tetrahedral grids with high-aspect-ratio cells is proposed. The method is based on new grid-marching strategy referred to as 'advancing-layers' for construction of highly stretched cells in the boundary layer and the conventional advancing-front technique for generation of regular, equilateral cells in the inviscid-flow region. Unlike the existing semi-structured viscous grid generation techniques, the new procedure relies on a totally unstructured advancing-front grid strategy resulting in a substantially enhanced grid flexibility and efficiency. The method is conceptually simple but powerful, capable of producing high quality viscous grids for complex configurations with ease. A number of two-dimensional, triangular grids are presented to demonstrate the methodology. The basic elements of the method, however, have been primarily designed with three-dimensional problems in mind, making it extendible for tetrahedral, viscous grid generation.

Pirzadeh, Shahyar↗