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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Mechanical properties testing and results for thermal barrier coatings

The paper reports on several years of mechanical testing of thermal barrier coatings. The test results were generated to support the development of durability models for the coatings in heat engine applications. The test data that are reviewed include modulus, static strength, and fatigue strength data. The test methods and results are discussed, along with the significant difficulties inherent in mechanical testing of thermal barrier coating materials. The materials include 7 percent wt. and 8 percent wt. yttria, partially stabilized zirconia as well as a cermet material. Both low pressure plasma spray and electron-beam physical vapor deposited coatings were tested. The data indicate the basic trends in the mechanical properties of the coatings over a wide range of isothermal conditions. Some of the trends are correlated with material density.

Thomas A. Cruse↗
DOE OSTI2021

A physics-informed data-driven low order model for the wind velocity deficit at the wake of isolated buildings

Detailed simulations of the Atmospheric boundary layer (ABL) provides information on wind velocity, direction and turbulence for optimizing the design of wind turbines and wind farms and their operations. Distributed wind turbines have been considered for use in urban or suburban areas for covering energy needs using a sustainable energy solution. Simulations of high Reynolds number turbulent ABL flows past obstacles can be used for the prediction of the velocity deficit and turbulence characteristics in the leeward side of building-like obstacles, allowing for the estimation of power losses and fatigue loads in wind turbines. However, fully three-dimensional simulations of high Reynolds number ABL flows using Large Eddy Simulation (LES) or Reynolds Average Navier-Stokes Simulations (RANS) continue to require large computational/ execution times. As a result, these 3D simulations may not be ideal tools for the rapid assessment of wind energy potential. In the present study, 3D numerical results from wall resolved RANS simulations were used for the development of a low order model that allows the rapid assessment of wind velocity and turbulence in the leeward side of an isolated building.

17 WIND ENERGY↗
NASA NTRS1981

Composite structural materials

Physical properties of fiber reinforced composites; structural concepts and analysis; manufacturing; reliability; and life prediction are subjects of research conducted to determine the long term integrity of composite aircraft structures under conditions pertinent to service use. Progress is reported in (1) characterizing homogeneity in composite materials; (2) developing methods for analyzing composite materials; (3) studying fatigue in composite materials; (4) determining the temperature and moisture effects on the mechanical properties of laminates; (5) numerically analyzing moisture effects; (6) numerically analyzing the micromechanics of composite fracture; (7) constructing the 727 elevator attachment rib; (8) developing the L-1011 engine drag strut (CAPCOMP 2 program); (9) analyzing mechanical joints in composites; (10) developing computer software; and (11) processing science and technology, with emphasis on the sailplane project.

Ansell, G. S.↗
NASA NTRS1987

Calculation of thermomechanical fatigue life based on isothermal behavior

The isothermal and thermomechanical fatigue (TMF) crack initiation response of a hypothetical material was analyzed. Expected thermomechanical behavior was evaluated numerically based on simple, isothermal, cyclic stress-strain - time characteristics and on strainrange versus cyclic life relations that have been assigned to the material. The attempt was made to establish basic minimum requirements for the development of a physically accurate TMF life-prediction model. A worthy method must be able to deal with the simplest of conditions: that is, those for which thermal cycling, per se, introduces no damage mechanisms other than those found in isothermal behavior. Under these assumed conditions, the TMF life should be obtained uniquely from known isothermal behavior. The ramifications of making more complex assumptions will be dealt with in future studies. Although analyses are only in their early stages, considerable insight has been gained in understanding the characteristics of several existing high-temperature life-prediction methods. The present work indicates that the most viable damage parameter is based on the inelastic strainrange.

Halford, Gary R.↗
NASA NTRS1987

Calculation of thermomechanical fatigue life based on isothermal behavior

The isothermal and thermomechanical fatigue (TMF) crack initiation response of a hypothetical material was analyzed. Expected thermomechanical behavior was evaluated numerically based on simple, isothermal, cyclic stress-strain-time characteristics and on strainrange versus cyclic life relations that have been assigned to the material. The attempt was made to establish basic minimum requirements for the development of a physically accurate TMF life-prediction model. A worthy method must be able to deal with the simplest of conditions: that is, those for which thermal cycling, per se, introduces no damage mechanisms other than those found in isothermal behavior. Under these assumed conditions, the TMF life should be obtained uniquely from known isothermal behavior. The ramifications of making more complex assumptions will be dealt with in future studies. Although analyses are only in their early stages, considerable insight has been gained in understanding the characteristics of several existing high-temperature life-prediction methods. The present work indicates that the most viable damage parameter is based on the inelastic strainrange.

Halford, G. R.↗
NASA NTRS2006

Studies of acoustic-electric feed-throughs for power transmission through structures

There are numerous engineering design problems where the use of wires to transfer power and communicate data thru the walls of a structure is prohibitive or significantly difficult that it may require a complex design. Using physical feedthroughs in such systems may make them susceptible to leakage of chemicals or gasses, loss of pressure or vacuum, as well as difficulties in providing adequate thermal or electrical insulation. Moreover, feeding wires thru a wall of a structure reduces the strength of the structure and makes the structure prone to cracking due to fatigue that can result from cyclic loading and stress concentrations. One area that has already been identified to require a wireless alternative to electrical feedthroughs is the container of the Mars Sample Return Mission, which will need wireless sensors to sense a pressure leak and to avoid potential contamination. The idea of using elastic or acoustic waves to transfer power was suggested recently by [Y. Hu, et al., July 2003]. This system allows for the avoidance of cabling or wiring. The technology is applicable to the transfer of power for actuation, sensing and other tasks inside any sealed container or vacuum/pressure vessel. An alternative approach to the modeling presented previously [Sherrit et a., 2005] used network analysis to solve the same problem in a clear and expandable manner. Experimental tests on three different designs of these devices were performed. The three designs used different methods of coupling the piezoelectric element to the wall. In the first test the piezoelectric material was bolted using a backing structure. In the second test the piezoelectric was clamped after the application of grease and finally the piezoelectric element was attached using a conductive epoxy. The mechanical clamp with grease produced the highest measured efficiency of 53% however this design was the least practical from a fabrication viewpoint. The power transfer efficiency of conductive epoxy joint was 40% and the stress bolts (12%).

ultrasonics↗
NASA NTRS2017

Structural Health Management of Damaged Aircraft Structures Using the Digital Twin Concept

The development of multidisciplinary integrated Structural Health Management (SHM) tools will enable accurate detection, and prognosis of damaged aircraft under normal and adverse conditions during flight. As part of the digital twin concept, methodologies are developed by using integrated multiphysics models, sensor information and input data from an in-service vehicle to mirror and predict the life of its corresponding physical twin. SHM tools are necessary for both damage diagnostics and prognostics for continued safe operation of damaged aircraft structures. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern in these structures is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable, catastrophic propagation of damage during a flight, load levels must be maintained that are below a reduced load-carrying capacity for continued safe operation of an aircraft. Hence, a capability is needed for accurate real-time predictions of damage size and safe load carrying capacity for structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size, location, and orientation is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size, location, and orientation is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries, and sizes.

Seshadri, Banavara R.↗
DOE OSTI2025

Coexisting Phases in NaNbO 3 Thin Films Influenced by Epitaxial Strain and Size Effects

Coherently strained NaNbO 3 thin films are synthesized across a range of thicknesses, enabling the study of size effects under epitaxial strain in antiferroelectric thin films without relaxation. Competing antiferroelectric‐ferroelectric phases are observed, leading to the stabilization of phase coexistence, multistate switching with strong retention and fatigue performance, and potential avenues to boost energy storage properties.

antiferroelectrics↗
DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Data Driven Approach to Dislocation-Based Plasticity Models of Face-Centered Cubic Metals

Dislocation dynamics controls plastic deformation, mechanical strength, and failure of crystalline materials. It also governs fatigue resistance under cyclic loading, creep resistance at elevated-temperature, and radiation resistance for reactor applications. There is a compelling need for understanding fundamental dislocation mechanisms for deformation because virtually all structural metals used in energy systems are fabricated to desired forms and shapes by deformation processes. To date, the most outstanding problem in a physics-based multiscale model of crystal plasticity is the lack of quantitative connections between continuum plasticity (CP) models with the lower scale dislocation models. As a result, existing CP models used in engineering applications are still phenomenological, while evidence continues to mount that they can make inaccurate predictions under realistically complex scenarios. This project takes advantage of the recent advances in high-performance discrete dislocation dynamics (DDD) simulations and data science approaches to establish the first fully connected multiscale plasticity model for pure face-centered cubic (FCC) single crystals.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Converging Indicators for Assessing Individual Differences in Adaptation to Extreme Environments: Preliminary Report

This paper describes the development and validation of a new methodology for assessing the deleterious effects of spaceflight on crew health and performance. It is well known that microgravity results in various physiological alterations, e.g., headward fluid shifts which can impede physiological adaptation. Other factors that may affect crew operational efficiency include disruption of sleep-wake cycles, high workload, isolation, confinement, stress and fatigue. From an operational perspective, it is difficult to predict which individuals will be most or least affected in this unique environment given that most astronauts are first-time flyers. During future lunar and Mars missions space crews will include both men and women of multi-national origins, different professional backgrounds, and various states of physical condition. Therefore, new methods or technologies are needed to monitor and predict astronaut performance and health, and to evaluate the effects of various countermeasures on crew during long duration missions. This paper reviews several studies conducted in both laboratory and operational environments with men and women ranging in age between 18 to 50 years. The studies included the following: soldiers performing command and control functions during mobile operations in enclosed armored vehicles; subjects participating in laboratory tests of an anti-motion sickness medication; subjects exposed to chronic hypergravity aboard a centrifuge, and subject responses to 36-hours of sleep deprivation. Physiological measurements, performance metrics, and subjective self-reports were collected in each study. The results demonstrate that multivariate converging indicators provide a significantly more reliable method for assessing environmental effects on performance and health than any single indicator.

Cowings, Patricia S.↗
NASA NTRS2020

Food Acceptability, Menu Fatigue, and Aversion on ISS Missions

The acceptability of the spaceflight food system has been linked to caloric intake and associated nutritional benefits. The diets of the United States Operating Segment crewmembers during a mission are restricted to 200 processed and prepackaged standard menu items supplemented with personal preference foods. ISS crew members have noted in debriefs that they would prefer more food variety for the length of the missions and they tire of certain foods over six months. It is possible that menu fatigue leads to decreases in acceptability and increased aversion to available foods, potentially contributing to the body mass loss often experienced by ISS crew. However, the impact of repeat food consumption on acceptability within the current spaceflight food system has not yet been systematically investigated. Limited variety and crew preferences within food categories may have more severe physical and behavioral health and performance consequences as mission duration increases. Characterizing the relationship between food acceptability and mission duration will contribute to defining requirements for an acceptable food system that will support crew health and performance on long duration missions.

Douglas, Grace L.↗
DOE OSTI2025

Design, Optimization, and Control of Floating Offshore Wind Farms for Optimal Energy Production (Final report)

The uncertainty and irregularity of ocean waves and the ocean environment is a major factor in the development of commercial scale floating wind turbines as the operation of floating structures in such an environment can lead to irregular and unpredictable loading, fatigue, and ultimately a reduction in the operational life of the turbine system which affects energy production over the lifetime of the turbine. Control solutions that can limit float motions and mitigate stressful events on the structure become essential for extending lifetime and limiting the operational uncertainty of a floating wind turbine. Digital twins are computational replicas of physical systems that operate in parallel with the operation of the physical system. Given advanced knowledge of a systems input, digital twins have the ability to predict the behavior of a system in advance, which can be valuable in the control of that system. In this project, we developed and assessed potential digital twin models developed in house and openly available (OpenFast) for use in the real time control of the six degree of freedom response motions of a floating wind turbine in ocean waves. Coupling these models with near-field real time irregular sea surface (wve) measurement/sensings and prediction models, we used the digital twin to predict how the floating turbine will respond to the incoming waves. Applying this information to a motion control system of the float, one can limit and control float motions to prevent undesirable loading events/large angular motions, thus increasing system life and ultimately contributing to optimizing energy production. Due to the computational intensity of operating a digital twin in real time, we investigated the use of artificial intelligence techniques to speed-up the processes of the digital twin, as well as the wave reconstruction/prediction models. Model tank testing at the University of Rhode Island and University of Maine both validated and demonstrated the developed techniques on simple float geometries and a scale model of the NREL 15 MW reference turbine.

17 WIND ENERGY↗
DOE OSTI2021

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades).

36 MATERIALS SCIENCE↗
NASA NTRS2023

NASA Space Environment Analog for Training, Engineering, Science, and Technology (SEATEST) 6 Detailed Final Report

After more than 50 years since the last crewed lunar landing, plans for more missions to the moon are in development. For these missions, efficient and sustainable logistics will be critical. Additionally, innovative methods of cargo transfer to and from a lunar outpost should be considered for successfully establishing a permanent presence on the moon. SEATEST (Space Environment Analog for Training, Engineering, Science, and Technology) is an immersive mission-analogous operational atmosphere where buoyancy effects and supplemental weights can simulate partial gravity conditions similar to those astronauts will experience on the moon. SEATEST 6 took place at the University of Southern California (USC) Wrigley Marine Science Center on Santa Catalina Island from July 18-30, 2023. The analog was used to collect preliminary logistics data on two different offloading conceptual methods (a davit and a zipline) during a simulated lunar mission. Pre-test analysis indicated for a crew of two on a 14-day mission, approximately three Medium Pressurized Logistics Containers (MPLC) sized logistics containers (or a total of 37.5 single Cargo Transfer Bag Equivalents (CTBE)) would be needed to support a mission. A Computer-Aided Design (CAD) analysis was employed on the SEATEST airlock mockup to determine how many logistic containers would fit with two suited crewmembers, don/doff stands, and hatch operations. It was determined that for SEATEST, a total of 15 1.0 Small Pressurized Logistics Containers (SPLCs) and 8 2.0 SPLCs would adequately fit into the approximate 9.5 cubic meter airlock volume. This does not fully represent a complete 14-day logistic supply; however, it does provide a preliminary estimate to initiate design conversations between logistics teams and crew at this early stage of development. Data were collected in eight logistics transfer scenarios over two days with four scenarios per day. Five test subject crew participated in scenarios as pairs. Scenarios included two sizes of logistics containers – 1.0 SPLC (equivalent to a single Cargo Transfer Bag (CTB) and 2.0 SPLC (equivalent to two CTBs). Planed evaluations included the use of a logistics port compared to transfer through an Airlock hatch, offloading methods based on either a davit or a zipline system, choreography of cargo in the airlock to permit ingress and suit doffing, and dust removal protocols for an understanding of the overall impact to transfer ops. Data collected included objective data (task times for conducting overall tasks and subtasks, full audio/video of test activities, and inadvertent “dings” on hardware) and subjective data (crew consensus of: task acceptability and capability assessment ratings related to best practices, considerations, and constraints for EVA-driven logistics transfer ConOps, sim quality of the test environment, and more general debrief comments). The two logistic offloading transfer concepts (davit, zipline) presented both advantages and limitations. The davit’s flexibility in allowing the crew to pick up the containers without physical interaction was well regarded by the crew. Some limitations of select davit hardware components were noted, but the overall concept was acceptable. The zipline system proved to be the most efficient way of moving logistics from the lander to the airlock and eliminated the need for dust operations. However, extended and repetitive lifting of containers to the line could be fatiguing. In conclusion, logistics transfer could hypothetically be achieved without an offloading method; however, the time requirement for such operations would be prohibitive. Results of crew subjective feedback proposed a combined or hybrid davit/zipline method to increase efficiency.

Logistics↗
DOE OSTI2025

Physics of wurtzite ferroelectrics

Ferroelectricity was long considered incompatible with the wurtzite structure, but the recent discovery of switchable polarization in wurtzite alloys has renewed interest in these materials for integrated electronic and memory applications. The development of wurtzite ferroelectrics faces significant technological challenges, which can be addressed through a fundamental physical understanding of their dielectric and ferroelectric properties. This article focuses on the physics that govern the polarization switching behavior, emphasizing the atomic- and meso-scale (domain) mechanisms involved in the transition between polarization states. A distinguishing feature of this article is a deep dive into the role of intrinsic and extrinsic defects—an area that has received limited attention in prior reviews, but is increasingly recognized as central to polarization switching, coercive fields, leakage, and fatigue. We highlight how defect behavior evolves during processing and electrical cycling, often contributing to long-term degradation. We also introduce powerful first-principles defect calculations, common in semiconductors but not yet widespread in ferroelectrics, as tools to understand and design materials. By integrating recent theoretical and experimental insights, we aim to provide a framework for advancing wurtzite ferroelectrics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2002

A Comparative Study of Three Methodologies for Modeling Dynamic Stall

During the past two decades, there has been an increased reliance on the use of computational fluid dynamics methods for modeling rotors in high speed forward flight. Computational methods are being developed for modeling the shock induced loads on the advancing side, first-principles based modeling of the trailing wake evolution, and for retreating blade stall. The retreating blade dynamic stall problem has received particular attention, because the large variations in lift and pitching moments encountered in dynamic stall can lead to blade vibrations and pitch link fatigue. Restricting to aerodynamics, the numerical prediction of dynamic stall is still a complex and challenging CFD problem, that, even in two dimensions at low speed, gathers the major difficulties of aerodynamics, such as the grid resolution requirements for the viscous phenomena at leading-edge bubbles or in mixing-layers, the bias of the numerical viscosity, and the major difficulties of the physical modeling, such as the turbulence models, the transition models, whose both determinant influences, already present in static maximal-lift or stall computations, are emphasized by the dynamic aspect of the phenomena.

Sankar, L.↗