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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
NASA NTRS2018

Characterizing Material Scalability for Ultralight Lattice Design

Stiff yet ultra-light lattice structures constructed using digital materials have many practical applications as the building block for aircraft and other structures. By furthering our understanding of how material configuration affects the structural properties of an ultralight lattice, we can intelligently design these structures based on their intended function. Here we compare the behavior of ultralight lattice structures when fabricated by different materials. The individual unit cells of the lattice structures are referred to as voxels. The stiffness, elastic modulus, and yield strength of the specimens in compression and tension are determined through mechanical testing. Specimens are tested both as single voxel as well as 4x4x4 voxel constructions on an Instron 5982 Universal Testing System until failure. Each voxel is manufactured in bulk through injection molding, with a unit cell pitch of 76.2 mm. Individual voxels are fastened with machine screws and nuts to create assemblies. Four separate materials are used as voxel compositions in this experiment. These include a homogeneous polymer referred to as Ultem 1000, a glass-fiber reinforced polymer referred to as Ultem 2200, a polymer with chopped carbon fibers as 30% of its fill, and homogenous polypropylene. This work compares mechanical behavior, as well as the convergence behavior of the lattice as the size of the lattice assembly increases for various materials. The goal of this study is to characterize the behavior of homogenous lattices such that heterogenous lattices can be designed with different material voxels to achieve target material properties for ultralight space applications.

Sajjadi, Afsheen↗
DOE OSTI2025

Beam optics ramping in underconstrained lattice design: Application to Electron-Ion Collider hadron storage ring cooling section

This paper presents the lattice design and optics ramping strategy for the cooling section of the hadron storage ring at the electron-ion collider. The main challenge is that available tuning knobs exceed beam-optics constraints. Independently optimized injection and top-energy optics often yield disconnected solutions, making interpolation impossible. To address this, we propose two new methods. The first is an intermediate-penalty scheme that ensures ramping path continuity by penalizing constraint violations at intermediate states. The second is a continuation-based approach that adapts high-energy optics to low energy, guided by an adaptive weighting scheme to balance injection and ramping constraints. The solutions meet all beam dynamics and hardware limits. The two methods offer a general strategy for ramping in systems where the solution space is under-constrained and the starting and target configurations are far apart.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Electron-Ion Collider (EIC) Hadron Storage Ring (HSR) Injection Transport Beamline (Y-Line Ext.) Lattice Design and Magnet Parameters

The preliminary design of the Electron-Ion Collider (EIC) Hadron Storage Ring (HSR) Normal Conducting Injection Beamline ( Y-Line Ext. ) lattice is discussed. The preliminary design includes the periodic cells, matching sections, state of the art Twiss parameters at the HSR injection, the magnet parameters and first order instrumentation placement. Furthermore, the beamline parameters, element coordinates, and other information are discussed. The names of the HSR Injection Beamline elements used in this technical report ( i.e. HD1, HQ1 ) are preliminary and not the official site wide names.

43 PARTICLE ACCELERATORS↗
NASA NTRS1922

Notes on the design of latticed columns subject to lateral loads

No rational column formula has yet been developed which gives results which are sufficiently precise for the design of airplane members, and consequently it is necessary to fall back upon experimental testing. In order to derive the maximum benefit from experiments, however, it is necessary that the experiments be guided by theory. It is the object here to modify existing formulae that may be obtained with a minimum number of tests. A discussion is given that is limited to the case of a simple column supported at both ends and subjected to uniformly distributed loads perpendicular to its axis and to end loads either axially or eccentrically applied. Discussed here are forces in the bracing of latticed columns, the application of theory to practical columns, loads in lattice members, and the strength of individual lattices.

Mccarthy, Charles J↗
NASA NTRS2007

Open-Lattice Composite Design Strengthens Structures

Advanced composite materials and designs could eventually be applied as the framework for spacecraft or extraterrestrial constructions for long-term space habitation. One such structure in which NASA has made an investment is the IsoTruss grid structure, an extension of a two-dimensional "isogrid" concept originally developed at McDonnell Douglas Astronautics Company, under contract to NASA's Marshall Space Flight Center in the early 1970s. IsoTruss is a lightweight and efficient alternative to monocoque composite structures, and can be produced in a manner that involves fairly simple techniques. The technology was developed with support from NASA to explore space applications, and is garnering global attention because it is extremely lightweight; as much as 12 times stronger than steel; inexpensive to manufacture, transport, and install; low-maintenance; and is fully recyclable. IsoTruss is expected to see application as utility poles and meteorological towers, for the aforementioned reasons and because its design offers superior wind resistance and is less susceptible to breaking and woodpeckers. Other applications, such as reinforcement for concrete structures, stand-alone towers, sign supports, prostheses, irrigation equipment, and sporting goods are being explored

Source record↗
NASA NTRS2026

Evaluation of Superalloy 718 Additively Manufactured Lattice Blocks

Lattice block structures made up of high temperature superalloys could offer advantages in density, efficiency, and tailored properties. Three candidate lattice designs were screened through additive manufacturing of superalloy 718. Laser powder bed fusion was applied with 718 powder to produce lattice blocks for three-dimensional octahedral unit cell designs of three heights. As-designed versus additively manufactured 718 lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Manufactured lattice I diverged the most from its design, with both corner and center nodes merged into continuous columns. Manufactured lattice III came closest to its design, though the actual nodes and struts were still larger in cross section than in the design. Only modest grain coarsening and negligible chemical segregation were observed for all three designs, suggesting uniform thermo-physical and mechanical properties are possible. Significant tensile residual stresses were present at the surface of the manufactured blocks, with highest stresses in the building direction. Current findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermo-physical/mechanical properties.

super alloys↗
NASA NTRS1981

Computer program documentation for a subcritical wing design code using higher order far-field drag minimization

A subsonic, linearized aerodynamic theory, wing design program for one or two planforms was developed which uses a vortex lattice near field model and a higher order panel method in the far field. The theoretical development of the wake model and its implementation in the vortex lattice design code are summarized and sample results are given. Detailed program usage instructions, sample input and output data, and a program listing are presented in the Appendixes. The far field wake model assumes a wake vortex sheet whose strength varies piecewise linearly in the spanwise direction. From this model analytical expressions for lift coefficient, induced drag coefficient, pitching moment coefficient, and bending moment coefficient were developed. From these relationships a direct optimization scheme is used to determine the optimum wake vorticity distribution for minimum induced drag, subject to constraints on lift, and pitching or bending moment. Integration spanwise yields the bound circulation, which is interpolated in the near field vortex lattice to obtain the design camber surface(s).

Kuhlman, J. M.↗
NASA NTRSDate not supplied

Evaluations of Additively Manufactured Superalloy Lattice Blocks

Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.

superalloy↗
DOE OSTI2026

Initial Assessment of 3D-Printed Molybdenum Lattices as a Substrate for Liquid Metal Plasma-Facing Components

Many liquid metal plasma-facing component concepts for fusion reactors require a capillary porous material to wick the liquid metal to the surface of the component. In this work, samples of 3D-printed molybdenum lattices designed to have pore sizes ranging from 100 to 1000 µm were fabricated by two different suppliers. The dimensions of the lattice structures were characterized using an optical microscope, revealing that the lattice walls were almost systematically thicker than they were designed to be and in turn the pores are all smaller than they were designed to be. In many cases the pores were completely clogged. Several spectroscopic techniques were used to characterize the chemical composition of the materials, collectively indicating the presence of a thick layer of oxygen-rich material extending more than 1 µm below the surface. Compression testing revealed significant asymmetry in the mechanical behavior depending on which direction the force was applied relative to the print direction. Lastly, lithium wetting tests of several lattice samples were performed, and a sample with ~250-µm pores was found to soak up lithium quickly after initial wetting of the surface occurred. The implications of these results for future liquid metal plasma-facing component design are discussed.

Parsons, Matthew S. [Princeton Plasma Physics Labo↗
DOE OSTI2025

Mechanical Properties and Interfacial Bonding of Overmolded Polymer Composite Lattice Structures

This study investigates the mechanical properties and interfacial bonding of Polyamide 12 filled with Glass Fiber (PA12/GF) lattice structures overmolded with Nylon 66 (PA66) and Thermoplastic Polyurethane (TPU). The PA12/GF lattices, designed in Gyroid, Isotruss, and Octahedral geometries, were produced using the Selective Laser Sintering (SLS) technique. The thermal characteristics of both the lattice and overmolding materials were analyzed using Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). The mechanical performance and interfacial bonding were evaluated through mechanical testing and microstructural analysis. The results indicate that overmolding improved flexural strength and impact resistance of the PA12/GF lattices. For instance, the plain PA12/GF Isotruss lattice exhibited a flexural strength of 15.5 MPa. By overmolding it with TPU the flexural strength increased by up to 137%, while PA66-overmolding resulted in an increase of 371%, achieving a flexural strength of 73 MPa. In terms of impact resistance, TPU-overmolding improved performance significantly, with an increase of 1800% (Gyroid) compared to the plain lattice. Microstructural analysis revealed good adhesion at the interface, especially when both the lattice and overmolding materials were thoroughly dried prior to the overmolding process to minimize interfacial porosity. This study highlights the potential of using overmolding to enhance lattice structures performance, offering lightweight and cost-efficient solutions for automotive applications.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
DOE OSTI2026

Spin Diagnostics Using Mott Polarimeter for the EIC Pre-Injector

Polarization measurement and front-end commissioning are critical steps in the EIC preinjector program. We designed a spin-diagnostics beamline at around 4 MeV for front-end commissioning. This paper describes a high-energy Mott polarimeter, including Mott scattering, the Sherman function, and extrapolation toward single elastic scattering in finite-thickness foils. We summarize the key equations used to calculate essential design parameters, including detection time, effective Sherman function, differential cross section, and Mott polarimeter figure of merit. We also present the diagnostics beamline lattice design and kicker design for continuous spin-polarization monitoring. These notes provide concepts, formulas, and methods for diagnostic-beamline design and commissioning measurements.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

The Sparks tracking code

This note introduces a new tracking code, Sparks, built on the foundations laid by hemod4 and designed for fast tracking of large ensembles of single particles over thousands of turns. The code is intended for the rapid evaluation of nonlinear lattice behavior through observables such as detuning, Poincaré sections, and smear, providing a computationally efficient alternative to large-scale dynamic aperture studies during lattice design and optimization.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗
DOE OSTI2026

Optimizing injection for the storage ring proton-EDM experiment

The proposed proton electric dipole moment (pEDM) experiment at Brookhaven National Laboratory (BNL), to be built inside the alternating gradient synchrotron (AGS) tunnel, aims to measure the proton’s electric dipole moment with a sensitivity of 10 −29 𝑒 cm. This paper presents the design of the injection line from the AGS booster to the pEDM storage ring, utilizing portions of the existing booster-to-AGS (BtA) transfer line. Building on the symmetric-hybrid lattice design [, Comprehensive symmetric-hybrid ring design for a proton-EDM experiment at below 10 −29 𝑒 cm, Phys. Rev. D 105, 032001 (2022)], our study emphasizes rigorous optics matching, detailed particle and spin tracking, and systematic error mitigation essential for achieving a target sensitivity of 10 −29 𝑒 cm. This design preserves the proton’s vertical spin orientation within ±20 mrad, a critical requirement for the pEDM measurement. Particle and spin tracking simulations using the ray-tracing code Zgoubi [F. Méot, Zgoubi users’ guide, Technical Report, Brookhaven National Laboratory (BNL), Relativistic Heavy Ion Collider (RHIC), Upton, NY, 2012] validate the design’s performance, demonstrating its feasibility for this precision experiment. The simulation results demonstrate that both clockwise (CW) and counterclockwise (CCW) injection lines meet the stringent beam envelope and polarization requirements.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Maximizing RHIC Deliverable Luminosity with Dynamic Telescopic Beta* Squeeze

To benefit fully from the exceptional performance of the Relativistic Heavy Ions Collider (RHIC) Stochastic Cooling system during heavy ions physics store, the betatron amplitude β ∗ at a given col lision point (IP) can be squeezed from its design value by using the available space in the quadrupole triplets from smaller beam emittances. This should allow reaching new heights in deliverable lumi nosity for both STAR and PHENIX experiments. Prior to 2014, RHIC lattice designs only squeezed the interaction regions (IR’s) down to β ∗ = 0.70 m. To get past this limitation, one can use a telescopic scheme where the non-experimental insertions surrounding STAR and PHENIX are used to generate and close a β-beat wave contributing to the final squeeze in the two IP’s of interest. The following presents the various steps of the implementation in RHIC of this telescopic scheme and the corresponding changes in collision rates and specific luminosity. A full feasibility study with a review of hardware and beam dynamics limitations is also included.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Synthetic Band Structure Engineering of Graphene Using Block Copolymer-Templated Dielectric Superlattices

Engineering the electronic band structure of two-dimensional (2D) materials by imposing spatially periodic superlattice (SL) potentials opens a pathway to unconventional electronics. Nanopatterning the gate electrode or surface dielectric near 2D crystals provides a powerful strategy for realizing electrostatically tunable “remote” SLs with flexibility in lattice design. Here, we demonstrate the effectiveness of block copolymer (BCP)-templated dielectric nanopatterns for fabricating etch-free high-grade metal oxide SLs. Alumina (AlO x ) nanopatterns with hexagonal symmetry and a 38 nm SL wavelength are produced as a model material by directly converting a self-assembled BCP film via block-selective vapor phase infiltration. Despite micrometer-scale rotational disorder inherent to BCP self-assembly, electronic transport measurements of graphene reveal replica Dirac points at zero field and Hofstadter mini-gaps under finite magnetic fields. These results indicate the successful formation of remote SL potentials in graphene resulting from optimized AlO x nanopattern fabrication to achieve consistent lattice symmetry and periodicity at a macroscopic scale. The findings of this study, combined with the versatile, scalable, and cost-effective nature of BCP nanopatterning, highlight the potential of BCP-templated nanostructures for remote SL engineering in 2D crystals.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Applying a Compact Porous Media Model to Numerically Derive Resistance Coefficients for Lattice Structures

Additive Manufacturing allows for exploring various geometries to achieve specific engineering criteria. Lattices are one geometry with unique properties, including being periodically repeating structures which allow flow through them to be represented as a porous media according to Darcy-Forchheimer equations. These equation’s coefficients are generally experimentally derived, but this work demonstrates the ability to numerically derive them with CFD. Simulations were performed using three-dimensional stead state Reynolds-averaged Navier-Stokes with a k-ω Shear Stress Transport turbulence model using Ansys Fluent. Three lattice geometries were investigated and drag coefficients were derived. The method was validated against externally published data for similar geometries demonstrating strong agreement, and grid convergence for all simulations was calculated with a Grid Convergence Index method. Wall roughness is demonstrated to have a non-negligible impact on results and roughness values are considered for the primary focus Octahedral geometry where both smooth wall and rough wall coefficients were derived. The porosity coefficients for the Octahedral geometry at 1.0 [m/s] were found to be 2.89×10 6 and 2.90×10 6 [1/(Pa*m*s)] for the permeability coefficients, 6.37×10 1 and 5.44×10 1 [m 2 /kg] for the inertial resistance coefficients, and with a max pressure drop of 5116.7 [Pa] and 4429.5 [Pa] for the smooth walls and rough walls, respectively. The derived numerical method enables rapid exploration and optimization of new lattice designs for diverse engineering applications.

42 ENGINEERING↗
DOE OSTI2026

Sextupole reduction via chaos suppression at the National Synchrotron Light Source II

We revisit the nonlinear lattice design approach for the National Synchrotron Light Source II (NSLS-II) storage ring. By suppressing chaos, we identify alternative sextupole configurations to the original design, which relied on the conventional strategy of simultaneously minimizing resonance driving terms (RDTs) and amplitude-dependent detuning (ADD). These alternatives achieve comparable performance while requiring fewer sextupoles. A detailed comparison of two representative solutions is presented and supported by experimental validation. Our results show that the dynamic aperture correlates more strongly with global chaos than with individual RDTs, and that the importance of minimizing ADD may have been overstated in earlier design strategies.

36 MATERIALS SCIENCE↗