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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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A consistent engine system data base was generated for defining advantages and disadvantages, system performance and operating limits, engine parametric data, and technology requirements for candidate high pressure LO2/HC engine systems. Optimum LO2/HC engine power cycles were synthetized and representative conceptual engine design generated for a specified advanced surface to orbit transportation system.
This Technology Commercialization Fund (TCF) CRADA involved demonstration of NREL modeling capability using OpenFAST (formerly known as FAST) to design the next generation of floating offshore wind turbines (FOTW) with Stiesdal’s TetraSpar design. The objective of the project was to enable the design and optimization of next generation FOWT that show promise to make FOWT cost-competitive with other energy technologies by upgrading, verifying, and validating improvements to OpenFAST. This objective was achieved by (1) upgrading OpenFAST to compute floating substructure flexibility and member-level loads, which is critical to enable the design of floating substructures—especially newer designs that are streamlined, flexible, and cost-effective; (2) verifying the new OpenFAST capabilities through model-to-model comparisons and validating the capabilities through comparisons to empirical data generated with wave-tank testing, using TetraSpar data provided by Stiesdal; and (3) making available the upgraded OpenFAST tool to the wind energy community to enable next-generation floating wind designs.
Splitting bioactive proteins into conditionally reconstituting fragments is a powerful strategy for building tools to study and control biological systems. However, split proteins often exhibit a high propensity to reconstitute, even without the conditional trigger, limiting their utility. Current approaches for tuning reconstitution propensity are laborious, context-specific or often ineffective. Here, we report a computational design strategy grounded in fundamental protein biophysics to guide experimental evaluation of a sparse set of mutants to identify an optimal functional window. We hypothesized that testing a limited set of mutants would direct subsequent mutagenesis efforts by predicting desirable mutant combinations from a vast mutational landscape. This strategy varies the degree of interfacial destabilization while preserving stability and catalytic activity. We validate our method by solving two distinct split protein design challenges, generating both design and mechanistic insights. Furthermore, this new technology will streamline the generation and use of split protein systems for diverse applications.
Here, the use of Printed Circuit Boards (PCBs) for the inductive pick-up windings of rotating coil probes has made the construction of these precision magnetic measurement devices much more accessible. This paper discusses the design details for PCBs which on each layer of the board provide for simultaneous analog bucking (suppression) of dipole, quadrupole, and sextupole field components so as to more accurately measure the higher order harmonic fields in sextupole magnets. Techniques to generate designs are discussed, as well as trade-offs to optimize sensitivity. Examples of recent sextupole PCBs and their performance are given.
A novel 6 MeV hybrid photo-injector has been designed and constructed, based on a smaller-scale prototype previously built in UCLA’s Particle Beam Physics Laboratory. It has been commissioned at Ariel University in Israel as an on-going collaboration between the two universities. This unique, new generation design provides a radically simpler approach to RF feeding of a gun/buncher system, leading to a much shorter beam via velocity bunching owed to an attached traveling wave section of the photo-injector. This design offers better performance in beam parameters, providing a high quality electron beam, with energy of 6 MeV. The hybrid photo-injector was designed to provide emittance of approximately 3 μm, and pulse duration of 150 fs at up to 1 nC per pulse. The hybrid gun is driven by a SLAC XK5 klystron as the high power RF source, and third harmonic of a ~35 fs IR Laser amplifier (266 nm) to extract electrons from the photo-cathode. The unique electron gun will produce a bunched electron pulse to drive a THz FEL, which will operate at the super-radiant regime, and therefore requires ambitious beam properties. This paper describes the gun and presents experimental results from the gun and its sub-systems, including energy and charge measurements, compared with the design simulations.
Abstract Carbon-negative synthesis of biochemical products has the potential to mitigate global CO 2 emissions. An attractive route to do this is the reverse β-oxidation (r-BOX) pathway coupled to the Wood-Ljungdahl pathway. Here, we optimize and implement r-BOX for the synthesis of C4-C6 acids and alcohols. With a high-throughput in vitro prototyping workflow, we screen 762 unique pathway combinations using cell-free extracts tailored for r-BOX to identify enzyme sets for enhanced product selectivity. Implementation of these pathways into Escherichia coli generates designer strains for the selective production of butanoic acid (4.9 ± 0.1 gL −1 ), as well as hexanoic acid (3.06 ± 0.03 gL −1 ) and 1-hexanol (1.0 ± 0.1 gL −1 ) at the best performance reported to date in this bacterium. We also generate Clostridium autoethanogenum strains able to produce 1-hexanol from syngas, achieving a titer of 0.26 gL −1 in a 1.5 L continuous fermentation. Our strategy enables optimization of r-BOX derived products for biomanufacturing and industrial biotechnology.
Design for Additive Manufacturing (DfAM) is widely used to describe design activities and guidelines employed in the creation of Additively Manufactured (AM) parts. Basic design rules for widely adopted processes like Powder Bed Fusion (PBF) are relatively understood including material performance, part size constraints, self-supporting angles, overhangs, wall thicknesses, and feature resolution. Complexity is often inherent with PBF using organically inspired solutions through generative design and topology optimization software to create designs that often cannot be realized via traditional manufacturing processes. The design rules for Directed Energy Deposition (DED) are less well known, and, in some cases, the lack of understanding is likely inhibiting broader application of the various DED processes. This presentation covers key design rules for DED fusion processes and elucidates opportunities like multi-material deposition and build approaches ranging from basic features to complex large-scale parts. Complementary to the opportunistic characteristics of DfAM for DED, Manufacture for AM (MfAM) encompasses the restrictive aspects of the manufacturing lifecycle with limitations due to bead width and wall thickness, self-supporting angles, surface texture, microstructural evolution, and residual stresses. AM enabled part design must always consider the entire value chain starting with incoming feedstock (e.g. plate, wire, or powder) and progressing through the printing process, post-processing (e.g. machining, inspection), and final system assembly. Key considerations, like the tradeoffs between feature resolution and build rate, for process and part selection and economic assessments will be discussed as DED is often traded against other AM processes. After highlighting typical DED design rules, we will also show how some of those rules can be broken via use cases and part designs that span the full spectrum of DED processes with examples of various DED part designs.
Bearings generate disturbances that, when combined with structural gains of a momentum wheel, contribute to induced vibration in the wheel. The frequencies generated by a ball bearing are defined by the bearing's geometry and defects. The amplitudes at these frequencies are dependent upon the actual geometry variations from perfection; therefore, a geometrically perfect bearing will produce no amplitudes at the kinematic frequencies that the design generates. Because perfect geometry can only be approached, emitted vibrations do occur. The most significant vibration is at the spin frequency and can be balanced out in the build process. Other frequencies' amplitudes, however, cannot be balanced out. Momentum wheels are usually the single largest source of vibrations in a spacecraft and can contribute to pointing inaccuracies if emitted vibrations ring the structure or are in the high-gain bandwidth of a sensitive pointing control loop. It is therefore important to be able to provide an a priori knowledge of possible amplitudes that are singular in source or are a result of interacting defects that do not reveal themselves in normal frequency prediction equations. This paper will describe the computer model that provides for the incorporation of bearing geometry errors and then develops an estimation of actual amplitudes and frequencies. Test results were correlated with the model. A momentum wheel was producing an unacceptable 74 Hz amplitude. The model was used to simulate geometry errors and proved successful in identifying a cause that was verified when the parts were inspected.
Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.
Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.
Superconducting magnets enable energy-frontier accelerators by generating strong magnetic fields to steer and focus the particles. Although high-temperature superconductors such as REBa 2 Cu 3 O x (, RE = rare earth) hold a strong potential for generating a higher magnetic field than Nb-Ti and Nb 3 Sn , the associated magnet and conductor technology for accelerator applications is still in its infancy. The U.S. Magnet Development Program is developing magnet technology in collaboration with industry. Here we report an experiment of making a dipole magnet called C3 using commercial high-temperature superconducting wires. The magnet, following a canted cos θ design, generated a dipole field of 5.99 T at 4.2 K in its clear aperture of 65 mm at 6.795 kA when a resistive voltage of 105 μ V appeared across one of the coils in the magnet. The stored energy was 53 kJ at the peak field. The magnet showed no degradation in the current-carrying capability at 4.2 K after the thermal cycle. We report on the detailed design, fabrication, and performance of the C3 magnet that can be of interest to potential users of this emerging technology. We also discuss issues and research needs to inform future magnet development. The experiment represented another step to addressing if the high-temperature superconducting accelerator magnet technology can increase the discovery capability of future particle accelerators.
We report in recent years, there has been an increased interest in 44Ti/44Sc generators as an onsite source of 44Sc for medical applications without needing a proximal cyclotron. The relatively short half-life (3.97 hours) and high positron branching ratio (94.3%) of 44Sc make it a viable candidate for positron emission tomography (PET) imaging. This review discusses current 44Ti/44Sc generator designs, focusing on their chemistry, drawbacks, post-elution processing, and relevant preclinical studies of the 44Sc for potential PET radiopharmaceuticals.
Some new developments relevant to the design of single-element airfoils using potential flow methods are presented. In particular, the ramifications of the unbounded trailing edge pressure gradients generally present in the potential flow solution for the flow over an airfoil are examined, and the conditions necessary to obtain a class of airfoils having finite trailing edge pressure gradients developed. The incorporation of these conditions into the inverse method of Eppler for the design of low-speed airfoils is discussed, and designs generated using the modified scheme are presented for consideration. A detailed viscous analysis of one of these airfoils demonstrates a significant reduction in the strong inviscid-viscid interactions generally present near the trailing edge. These reductions offer the possibility of improved airfoil performance, as well as the possibility of improved accuracy in the methods of airfoil design and analysis.
The specification and drawings present a new method, system and software product for and apparatus for generating a robotic validation system for a robot design. The robotic validation system for the robot design of a robotic system is automatically generated by converting a robot design into a generic robotic description using a predetermined format, then generating a control system from the generic robotic description and finally updating robot design parameters of the robotic system with an analysis tool using both the generic robot description and the control system.
The NASA Dryden Flight Research Facility has developed a microprocessor-based, user-programmable, general-purpose aircraft interrogation and display system (AIDS). The hardware and software of this ground-support equipment have been designed to permit diverse applications in support of aircraft digital flight-control systems and simulation facilities. AIDS is often employed to provide engineering-units display of internal digital system parameters during development and qualification testing. Such visibility into the system under test has proved to be a key element in the final qualification testing of aircraft digital flight-control systems. Three first-generation 8-bit units are now in service in support of several research aircraft projects, and user acceptance has been high. A second-generation design, extended AIDS (XAIDS), incorporating multiple 16-bit processors, is now being developed to support the forward swept wing aircraft project (X-29A). This paper outlines the AIDS concept, summarizes AIDS operational experience, and describes the planned XAIDS design and mechanization.
The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.
The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.
This research program established a transformative framework for the discovery and design of mechanical metamaterials, which are architected structures engineered to control physical phenomena like sound and vibration in ways natural materials cannot. To overcome the traditional reliance on trial-and-error, the project developed an interpretable Artificial Intelligence (AI) framework that moves beyond "black box" models to reveal the specific geometric patterns—such as "unit-cell templates"—that govern a material’s performance. A major breakthrough was the development of a hierarchical design method, which allows a single material to block vibrations across multiple frequency ranges simultaneously by layering patterns at different scales without them interfering with one another. This was further expanded to include irregular, graph-based designs that use spanning tree algorithms to ensure structural connectivity while allowing for customized, direction-dependent properties like stiffness and acoustic impedance. Beyond design, the project addressed the practicalities of real-world production by developing uncertainty quantification techniques that account for manufacturing defects and material variability, reducing the need for expensive physical testing by orders of magnitude. To speed up the discovery process, the team implemented Gaussian Process Regression and other surrogate models that provide accurate performance predictions at a fraction of the traditional computational cost. The AI-generated designs were successfully validated through fabrication of physical samples and wave propagation experiments, confirming their ability to accurately guide or reflect waves as predicted. By contributing these tools and high-quality FAIR benchmark datasets to the wider scientific community, this work provides a scalable foundation for advancing technologies in aerospace vibration control, medical imaging, and noise reduction.