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Results for “run-to-run”

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 OSTI2025

A Robust Data-Driven Approach for Mechanical Serial Sectioning

Mechanical serial sectioning (MSS) provides detailed microstructural information across large length scales. By repeatedly removing thin layers of material and imaging the exposed surface, a 3D representation of a specimen’s internal structure can be constructed, enabling failure analysis and feature identification that are otherwise inaccessible via conventional 2D or nondestructive evaluation techniques. Achieving consistent and accurate material removal can be challenging due to system variability, requiring an experienced operator to manually adjust parameters, prolonging data collection times and necessitating post-processing routines to standardize the data. Here, to address these challenges, this paper presents the employment of a one-step model predictive control (MPC) framework tailored to a run-to-run (R2R) controller. The R2R-MPC controller automates the parameter selection process, improving the consistency of material removal through iterative feedback for disturbance rejection and accurate tracking of the target removal rate. Using a data-driven approach, the controller robustly adapts to changing material characteristics. The effectiveness of the R2R-MPC controller is demonstrated through simulation and experimental results and compared to previous data collection procedures.

3D Materials Science↗
DOE OSTI2025

Autonomous Nanoparticle Synthesis Guided by In Situ Multiscale Structural Characterization

Autonomous synthesis platforms promise rapid exploration of vast parameter spaces; yet, integrating in situ structural characterization in closed-loop synthesis optimization remains challenging. We demonstrate a realization of such a closed-loop platform coupled with a droplet-flow microreactor, in situ X-ray scattering methods (SAXS/WAXS), and Gaussian process optimization to synthesize citrate-reduced Au nanoparticles with targeted characteristics. The system efficiently explored ∼19,000 synthesis recipes through 365 experiments, achieving precise control over size (4–60 nm) and polydispersity (σ < 0.11) across large citrate/gold ratios, exceeding traditional synthesis boundaries (1–10). Beyond confirming classical Turkevich–Frens trends, partial-dependence analysis revealed strong nonlinear coupling among precursor, citrate, and pH effects. Combining quantitative SAXS/WAXS analysis with electron microscopy characterization, we uncovered that crystallite size (d c ) and particle size (d) follow d c = 0.18d + β, where synthesis chemistry controls the intercept β while maintaining a universal slope. This parallel-band structure enables independent tuning of crystallite domain size at fixed particle diameter through a combination of chloride, gold precursor, citrate, and pH contributions (cross-validated Spearman ρ = 0.7 ± 0.1). High-resolution electron microscopy shows multiple lattice-fringe orientations within single particles, directly confirming polycrystalline domains and the ability to tune d c at the fixed d. The platform’s validation includes indistinguishable static versus flowing measurements, stable droplet transport at 100 °C, and <5% run-to-run variation, establishing a robust framework for mapping and controlling multiscale nanoparticle structure across expansive chemical spaces. In conclusion, the developed closed-loop platform can be applied to a borad range of nanosyntheis processes.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Simultaneous x-ray diffraction measurements of nine pressure calibrants to 140 GPa

Accurate pressure calibration is fundamental to quantitative high-pressure science, yet inconsistencies among widely used secondary pressure scales persist. In this work, we report simultaneous synchrotron x-ray diffraction meatogether in diamond anvil cells to 140 GPa. This simultaneous-measurement strategy minimizes transitive errors and run-to-run inconsistencies inherent to paired-measurement approaches, yielding direct experimental volume-volume (V-V) relations among the calibrants. These V-V relations link the compression state of each phase to that of every other phase measured in the same experiment. By anchoring these V-V relations to the reduced 300 K equation of state (EOS) of copper derived from ramp-compression measurements, we derive an internally consistent set of Cu-referenced pressure scales via Vinet EOS fits. Because the primary experimental result is the V-V dataset, it provides an EOS-independent constraint that can be rereferenced if primary standards are revised. The dataset further enables a direct experimental cross-check of consistency between the adopted reduced 300 K Cu EOS and the corresponding reduced 300 K ramp-derived EOSs for Pt, Au, Ta, and hcp-Fe under a fixed V-V constraint. The residuals quantify small, material-dependent mismatches between each phase EOS and the Cu reference EOS.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Robust Data-Driven Predictive Run-to-Run Control for Automated Serial Sectioning

This letter presents a one-step predictive run-to-run controller (R2R-MPC) for the automation of mechanical serial sectioning (MSS), a destructive material analysis process. To address the inherent uncertainty and disturbances in the MSS process, a robust closed-loop approach is presented. Here, the robust R2R-MPC models the uncertainty of the MSS process using a linear differential inclusion. As an analytical model of the MSS process is unavailable, the differential inclusion is identified from historical data. The R2R-MPC is posed as an optimization problem that computes incremental changes to the control input which minimize the worst-case material removal errors. This optimization-based controller is combined with a run-to-run controller to provide integral action that rejects constant disturbances and tracks constant reference removal rates. To demonstrate the efficacy of our robust R2R-MPC, we present simulation results which compare the presented controller with a conventional non-robust R2R.

42 ENGINEERING↗
DOE OSTI2026

Structure-aware Initialization via Numerical Continuation and Informed Priors

Scientific machine learning (SciML) often operates in ill-conditioned, weakly identifiable regimes due to limited data or indirect observations. In such settings, optimization and inference are highly sensitive to the starting point, making initialization--often under-reported--a consequential degree of freedom. Random initialization is not a neutral default as it induces an implicit prior over candidate solutions and can systematically bias the result, producing large run-to-run variability. Here, we formalize this view by treating initialization as a hidden confounder in SciML and develop a unifying theory for structure-aware initialization via numerical continuation, constructing warm starts from related problem instances. Across representative tasks, including physics-informed neural networks, maximum likelihood estimation, and variational inference, warm starts have been shown to consistently reduce optimization effort and improve reliability.

Data integrity↗
DOE OSTI2025

Variance Preserving Spectral Subsampling

Generating statistically faithful short-duration gamma-ray spectra from a single long measurement is essential in nuclear safeguards, supporting tasks such as algorithm development and machine-learning applications, especially when list-mode data are unavailable. Existing subsampling methods often distort the statistical characteristics of genuine short-duration measurements, leading to biased or unreliable analytical outcomes and thereby undermining downstream tasks. In this work, we compare five subsampling approaches using a benchmark set of 156 genuine replicate spectra collected with a high-purity germanium detector. We evaluate each method with respect to run-to-run variance, channel-to-channel variance, and preservation of total counts (losslessness). Across a wide range of subsampling ratios, only binomial subsampling without replacement consistently reproduces the statistical properties of genuine short-duration spectra, maintaining proper dispersion even in sparse spectral regions and perfectly preserving total counts. These results provide a mathematically principled and practically validated framework for generating synthetically shortened spectra when true short-duration measurements are unavailable.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
NASA NTRS1976

Results of test MA22 in the NASA/LaRC 31-inch CFHT on an 0.010-scale model (32-0) of the space shuttle configuration 3 to determine RCS jet flow field interaction, volume 1

A wind tunnel test was conducted in the Langley Research Center 31-inch Continuous Flow Hypersonic Wind Tunnel from May 6, 1975 through June 3, 1975. The primary objectives of this test were the following: (1) to study the ability of the wind tunnel to repeat, on a run-to-run basis, data taken for identical configurations to determine if errors in repeatability could have a significant effect on jet interaction data, (2) to determine the effect of aerodynamic heating of the scale model on jet interaction, (3) to investigate the effects of elevon and body flap deflections on jet interaction, (4) to determine if the effects from jets fired separately along different axes can be added to equal the effects of the jets fired simultaneously (super position effects), (5) to study multiple jet effects, and (6) to investigate area ratio effects, i.e., the effect on jet interaction measurements of using wind tunnel nozzles with different area ratios in the same location. The model used in the test was a .010-scale model of the Space Shuttle Orbiter Configuration 3. The test was conducted at Mach 10.3 and a dynamic pressure of 150 psf. RCS chamber pressure was varied to simulate free flight dynamic pressures of 5, 7.5, 10, and 20 psf.

Kanipe, D. B.↗
NASA NTRS1989

Low-cost DH and quantum well laser array development

The intial results of a program aimed at developing low-cost diode laser arrays for use as solid-state laser pumps are reported. MOCVD is used to demonstrate excellent run-to-run reproducibility in emission wavelength, threshold current density, and quantum efficiency. For this first experimental series, J(th) values of approximately 1310 Amps/sq cm were obtained for broad-area unthinned devices from the growth runs. Differential quantum efficiencies of between 41 percent and 47 percent were measured on the non-facet-coated devices from all four runs. Single quantum well, separate confinement heterostructure lasers fabricated from wafers grown in the same MOCVD reactor exhibited near single-mode emission, with J(th) values of approximately 300 Amps/sq cm. Photoluminescence data confirm quantum well widths of 80 A and 150 A for two different MOCVD growth runs.

Linden, Kurt J.↗
NASA NTRS1992

Combustion-wave ignition for rocket engines

The combustion wave ignition concept was experimentally studied in order to verify its suitability for application in baffled sections of a large booster engine combustion chamber. Gaseous oxygen/gaseous methane (GOX/GH4) and gaseous oxygen/gaseous hydrogen (GOX/GH2) propellant combinations were evaluated in a subscale combustion wave ignition system. The system included four element tubes capable of carrying ignition energy simultaneously to four locations, simulating four baffled sections. Also, direct ignition of a simulated Main Combustion Chamber (MCC) was performed. Tests were conducted over a range of mixture ratios and tube geometries. Ignition was consistently attained over a wide range of mixture ratios. And at every ignition, the flame propagated through all four element tubes. For GOX/GH4, the ignition system ignited the MCC flow at mixture ratios from 2 to 10 and for GOX/GH2 the ratios is from 2 to 13. The ignition timing was found to be rapid and uniform. The total ignition delay when using the MCC was under 11 ms, with the tube-to-tube, as well as the run-to-run, variation under 1 ms. Tube geometries were found to have negligible effect on the ignition outcome and timing.

Liou, Larry C.↗
NASA NTRS1992

High heat flux measurements and experimental calibrations/characterizations

Recent progress in techniques employed in the measurement of very high heat-transfer rates in reentry-type facilities at the Arnold Engineering Development Center (AEDC) is described. These advances include thermal analyses applied to transducer concepts used to make these measurements; improved heat-flux sensor fabrication methods, equipment, and procedures for determining the experimental time response of individual sensors; performance of absolute heat-flux calibrations at levels above 2,000 Btu/cu ft-sec (2.27 kW/cu cm); and innovative methods of performing in-situ run-to-run characterizations of heat-flux probes installed in the test facility. Graphical illustrations of the results of extensive thermal analyses of the null-point calorimeter and coaxial surface thermocouple concepts with application to measurements in aerothermal test environments are presented. Results of time response experiments and absolute calibrations of null-point calorimeters and coaxial thermocouples performed in the laboratory at intermediate to high heat-flux levels are shown. Typical AEDC high-enthalpy arc heater heat-flux data recently obtained with a Calspan-fabricated null-point probe model are included.

Kidd, Carl T.↗
NASA NTRS1993

The use of designed experiments in the process development of continuous propellant mixing

A continuous mix pilot plant was constructed at Aerojet Propulsion Division in Sacramento, California to develop a robust propellant mixing process for the full scale plant that was to be built at the NASA Advanced Solid Rocket Motor facility Yellow Creek, Mississippi. The plant was used to conduct dozens of subsystem and full system mixing tests for evaluation of equipment, processing methods, and control schemes for later use at the production plant. As a culmination to this work, a series of designed experiments were conducted using an eight run Taguchi analysis with four factors at two levels each to determine the primary effect of processing parameters on propellant ballistic and mechanical properties. The factors examined in these runs included the propellant production rate (454 (1000) and 622 kg/hr (1371 Ib/hr)), the product temperature out of the mixer (49 (120) and 63 deg C (145 deg F)), mixer screw speed (75 and 90 rpm), and the deaerator excess capacity (20 and 80 percent). Measured response variables included the uncured and cured density, Crawford Bomb liquid strand burning rates, and selected mechanical properties. The experiment revealed that several of the response variables displayed significant changes from run-to-run with the product temperature being the single most important factor. After concluding this experiment, a twenty-six hour confirmation run was conducted to verify the conclusions reached in the designed experiment. The extended run produced over 12,250 kgs (27,000 lbs) of propellant meeting all of the pre-run targeted properties including density (1.803 g/cc (0.065 lb/in(exp 3)) with a 0.12 percent coefficient of variation (CV) at 25 deg C (77 deg F)), liquid strand burn rate (0.889 cm/s (0.350 in/s) with a 0.69 percent CV at 4210 KPa (610 psig), 15.6 deg C (60 deg F)), nominal maximum stress (828 KPa (120 psig) with a 2.84 percent CV, S&E at 25 deg C (77 deg F), 5.08 cm/min (2 in/min)), strain at nominal maximum (47.4 percent with a 3.96 percent CV), and initial tangent modulus (5349 KPa (775 psig) with a 7.26 percent CV).

Campbell, J. A.↗
NASA NTRS1996

Wing Twist Measurements at the National Transonic Facility

A technique for measuring wing twist currently in use at the National Transonic Facility is described. The technique is based upon a single camera photogrammetric determination of two dimensional coordinates with a fixed (and known) third dimensional coordinate. The wing twist is found from a conformal transformation between wind-on and wind-off 2-D coordinates in the plane of rotation. The advantages and limitations of the technique as well as the rationale for selection of this particular technique are discussed. Examples are presented to illustrate run-to-run and test-to-test repeatability of the technique in air mode. Examples of wing twist in cryogenic nitrogen mode are also presented.

Burner, Alpheus W.↗
NASA NTRS2000

Very High Current Density Nb/AlN/Nb Tunnel Junctions for Low-Noise Submillimeter Mixers

We have fabricated and tested submillimeter-wave superconductor-insulator-superconductor (SIS) mixers using very high current density Nb/AlN/Nb tunnel junctions (J(sub c) approximately equal 30 kA/sq cm) . The junctions have low resistance-area products (R(sub N)A approximately 5.6 Omega.sq micron), good subgap to normal resistance ratios R(sub sg)/R(sub N) approximately equal 10, and good run-to-run reproducibility. From Fourier transform spectrometer measurements, we infer that omega.R(sub N)C = 1 at 270 GHz. This is a factor of 2.5 improvement over what is generally available with Nb/AlO(x)/Nb junctions suitable for low-noise mixers. The AlN-barrier junctions are indeed capable of low-noise operation: we measure an uncorrected receiver noise temperature of T(sub RX) = 110 K (DSB) at 533 GHz for an unoptimized device. In addition to providing wider bandwidth operation at lower frequencies, the AlN-barrier junctions will considerably improve the performance of THz SIS mixers by reducing RF loss in the tuning circuits.

Kawamura, Jonathan↗
NASA NTRS1999

Model Deformation Measurement Technique NASA Langley HSR Experiences

Model deformation measurement techniques have been investigated and developed at NASA's Langley Research Center. The current technique is based upon a single video camera photogrammetric determination of two dimensional coordinates of wing targets with a fixed (and known) third dimensional coordinate, namely the spanwise location. Variations of this technique have been used to measure wing twist and bending at a few selected spanwise locations near the wing tip on HSR models at the National Transonic Facility, the Transonic Dynamics Tunnel, and the Unitary Plan Wind Tunnel. Automated measurements have been made at both the Transonic Dynamics Tunnel and at Unitary Plan Wind Tunnel during the past year. Automated measurements were made for the first time at the NTF during the recently completed HSR Reference H Test 78 in early 1996. A major problem in automation for the NTF has been the need for high contrast targets which do not exceed the stringent surface finish requirements. The advantages and limitations (including targeting) of the technique as well as the rationale for selection of this particular technique are discussed. Wing twist examples from the HSR Reference H model are presented to illustrate the run-to-run and test-to-test repeatability of the technique in air mode at the NTF. Examples of wing twist in cryogenic nitrogen mode at the NTF are also presented.

Burner, A. W.↗
NASA NTRS2001

Detection of Chamber Conditioning Through Optical Emission and Impedance Measurements

During oxide etch processes, buildup of fluorocarbon residues on reactor sidewalls can cause run-to-run drift and will necessitate some time for conditioning and seasoning of the reactor. Though diagnostics can be applied to study and understand these phenomena, many of them are not practical for use in an industrial reactor. For instance, measurements of ion fluxes and energy by mass spectrometry show that the buildup of insulating fluorocarbon films on the reactor surface will cause a shift in both ion energy and current in an argon plasma. However, such a device cannot be easily integrated into a processing system. The shift in ion energy and flux will be accompanied by an increase in the capacitance of the plasma sheath. The shift in sheath capacitance can be easily measured by a common commercially available impedance probe placed on the inductive coil. A buildup of film on the chamber wall is expected to affect the production of fluorocarbon radicals, and thus the presence of such species in the optical emission spectrum of the plasma can be monitored as well. These two techniques are employed on a GEC (Gaseous Electronics Conference) Reference Cell to assess the validity of optical emission and impedance monitoring as a metric of chamber conditioning. These techniques are applied to experimental runs with CHF3 and CHF3/O2/Ar plasmas, with intermediate monitoring of pure argon plasmas as a reference case for chamber conditions.

Cruden, Brett A.↗
NASA NTRS2008

Detailed Uncertainty Analysis for Ares I Ascent Aerodynamics Wind Tunnel Database

A detailed uncertainty analysis for the Ares I ascent aero 6-DOF wind tunnel database is described. While the database itself is determined using only the test results for the latest configuration, the data used for the uncertainty analysis comes from four tests on two different configurations at the Boeing Polysonic Wind Tunnel in St. Louis and the Unitary Plan Wind Tunnel at NASA Langley Research Center. Four major error sources are considered: (1) systematic errors from the balance calibration curve fits and model + balance installation, (2) run-to-run repeatability, (3) boundary-layer transition fixing, and (4) tunnel-to-tunnel reproducibility.

Hemsch, Michael J.↗
NASA NTRS2011

Supersonic Retro-Propulsion Experimental Design for Computational Fluid Dynamics Model Validation

The development of supersonic retro-propulsion, an enabling technology for heavy payload exploration missions to Mars, is the primary focus for the present paper. A new experimental model, intended to provide computational fluid dynamics model validation data, was recently designed for the Langley Research Center Unitary Plan Wind Tunnel Test Section 2. Pre-test computations were instrumental for sizing and refining the model, over the Mach number range of 2.4 to 4.6, such that tunnel blockage and internal flow separation issues would be minimized. A 5-in diameter 70-deg sphere-cone forebody, which accommodates up to four 4:1 area ratio nozzles, followed by a 10-in long cylindrical aftbody was developed for this study based on the computational results. The model was designed to allow for a large number of surface pressure measurements on the forebody and aftbody. Supplemental data included high-speed Schlieren video and internal pressures and temperatures. The run matrix was developed to allow for the quantification of various sources of experimental uncertainty, such as random errors due to run-to-run variations and bias errors due to flow field or model misalignments. Some preliminary results and observations from the test are presented, although detailed analyses of the data and uncertainties are still on going.

Berry, Scott A.↗