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DOE OSTI2025

ULTIMATE Phase I project: Development of Niobium-based alloys for Turbine Applications

Current Ni-based alloys used in turbine blade applications are operating at 1100°C which is approximately 90% of the solidus of Ni-based alloys. Further increases in temperature can be achieved only through the use of alloys with higher solidus temperatures such as refractory alloys which include Mo, Nb, W, Ta alloys. Niobium has a unique combination of physical properties that include a high melting point (2468°C), lowest density (8.57 g/cc), and the lowest modulus amongst refractory alloys, a good thermal conductivity that increases from 45 W/mK at room temperature to 62 W/mK at 1093°C, good ductility with fabricability using traditional techniques, high strength, good creep resistance, and general chemical inactivity. Hence niobium alloys offer many advantages for use at the desired temperature of 1300°C. One of the major deterrents to the use of niobium and its alloys at high temperatures is achieving good oxidation resistance. In addition, achieving balanced properties of room temperature strength, ductility, fracture toughness, high temperature strength, and creep resistance required for 1300°C operation at a density of 9 g/cm 3 is extremely challenging since the addition of W which is a potent strengthener increases the density of the alloy. This project seeks to enable the development of a tri-layered turbine blade that can operate continuously at 1300°C with the core of the turbine blade providing good creep resistance, the second layer providing improved oxidation resistance over the core layer, and the third layer being an environmental barrier providing oxidation resistance. The objective of this Phase 1 project was to use computational modeling and advanced characterization tools to develop two classes of Nb alloys which could be used as the core layer and the transition layer. The first class of alloys developed in this project was a Nb-alloy designed to serve as the turbine blade core with excellent room temperature strength, ductility, and high temperature strength and creep resistance required for 1300°C operation. These alloys were designed to contain sufficient solute solution strengthening elements (W, Mo) but constrained by the density of alloy, along with the addition of elements such as Zr, Hf, Ta, C, and N to achieve a combination of primary and secondary carbide precipitation. A total of 38 “creep-resistant” alloys were designed and cast during the duration of the project. Processing techniques were developed to keep the oxygen contents as low as possible with typical oxygen contents less than 250 ppm. One alloy with a density of < 9.5 g/cc was successful in meeting the Phase 2 intermediate project mechanical property milestone requirements of room temperature ductility greater than 1.0%, 1200°C creep strain of less than 3% at 150 MPa and 100 hours in vacuum, and with solidus temperature greater than 1500ᵒC. The second class of alloys was designed to be a Nb-rich alloy with improved oxidation resistance when compared to the core layer and was designed specifically to be compatible with the core layer and the outer environmental barrier coating. This Nb- alloy will be specifically designed to be microstructurally stable at these temperatures when in contact with the core alloy and provide protection against catastrophic failure of the barrier coating. Two alloys were cast and processed but further development was discontinued to focus on the development of the creep resistant alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Powder‐to‐Film Conversion of Nickel Single‐Atom Catalysts into Binder‐Free and Resistant Electrodes

Although a few binder-free and self-supported single-atom electrodes have been reported, achieving mechanically robust, defect-engineered, and reproducible films that preserve atomic dispersion under electrochemical operation remains challenging. This work addresses this limitation by presenting a versatile and generalizable strategy to transform powders into standalone, defect-engineered thin films hosting atomically dispersed Ni centers within conductive 2D frameworks. The physicochemical and electronic properties of these materials are thoroughly characterized using a comprehensive set of spectroscopic and microscopic techniques and confirmed the homogeneous dispersion and monoatomic nature of the Ni centers (0.94 wt.%) on the electrode films. Electrochemical testing via cyclic voltammetry and electrochemical impedance spectroscopy under a range of experimental conditions revealed that integration of Ni single atoms markedly enhanced performance and stability compared to carbon nanotube-only electrodes, maintaining integrity after 15 h of continuous operation. This improvement is accompanied by a notable reduction in charge transfer resistance (30.50 Ω) and an increase in double-layer capacitance (295.45 µF). Post-electrochemical analyses corroborated the structural integrity and robustness of the electrodes. Overall, this work bridges atomically precise catalysis and device-level electrochemistry, opening a route toward reproducible and scalable single-atom electrodes for sensing and energy conversion.

36 MATERIALS SCIENCE↗

NASA NTRS2007

The EBIT Calorimeter Spectrometer: A New, Permanent User Facility at the LLNL EBIT

The EBIT Calorimeter Spectrometer (ECS) has recently been completed and is currently being installed at the EBIT facility at the Lawrence Livermore National Laboratory. The ECS will replace the smaller XRS/EBIT spectrometer that has been in almost continuous operation since 2000. The XRS/EBIT was based on a spare laboratory cryostat and an engineering model detector system from the Suzaku/XRS observatory. The new ECS spectrometer was built from the ground up to be a low maintenance, high performance microcalorimeter spectrometer with 4 eV resolution at 6 keV, 32 detector channels, 10 us event timing, and capable of uninterrupted acquisition sessions of over 70 hours at 50 mK. The XRSIEBIT program has been extremely successful, producing over two-dozen refereed publications on topics such as laboratory astrophysics, atomic physics, nuclear physics, and calibration of the spectrometers for the National Ignition Facility, with many more publications in preparation. The ECS spectrometer will continue this work into the future with improved spectral resolution, integration times, and ease-of-use. We designed the ECS instrument with TES detectors in mind by using the same highly successful magnetic shielding as our laboratory TES cryostats. This design will lead to a future TES instrument at the LLNL EBIT. This proposed future instrument would include a hybrid detector system with 0.8 eV resolution in the band from 0.1-1.0 keV, 2 eV from 0.1-10 keV, and 30 eV from 0.5-100 keV, with high quantum efficiency in each band. Here we discuss the legacy of the XRS/EBIT program, the performance of the new ECS spectrometer, and plans for a future TES spectrometer.

Porter, S.↗

NASA NTRS1928

The relative performance obtained with several methods of control of an overcompressed engine using gasoline

This report presents some results obtained during an investigation to determine the relative characteristics for several methods of control of an overcompressed engine using gasoline and operating under sea-level conditions. For this work, a special single cylinder test engine, 5-inch bore by 7-inch stroke, and designed for ready adjustment of compression ratio, valve timing and valve lift while running, was used. This engine has been fully described in NACA-TR-250. Tests were made at an engine speed of 1,400 R. P. M. for compression ratios ranging from 4.0 to 7.6. The air-fuel ratios were on the rich side of the chemically correct mixture and were approximately those giving maximum power. When using plain domestic gasoline, detonation was controlled to a constant, predetermined amount (audible), such as would be permissible for continuous operation, by (a) throttling the carburetor, (b) maintaining full throttle but greatly retarding the ignition, and (c) varying the timing of the inlet valve to reduce the effective compression ratio. From the results of the tests, it may be concluded that method (b) gives the best all-round performance and, being easily employed in service, appears to be the most practicable method for controlling an overcompressed engine using gasoline at low altitudes.

Gardiner, Arthur W↗

NASA NTRS2014

Embedded Data Acquisition Tools for Rotorcraft Diagnostic Sensors

Rotorcraft drive trains must withstand enormous pressure while operating continuously in extreme temperature and vibration environments. Captive components, such as planetary and spiral bevel gears, see enormous strain but are not accessible to fixed instrumentation, such as a piezoelectric transducer. Thus, it is difficult to directly monitor components that are most susceptible to damage. This innovation is a self-contained data processing unit within a specialized fixture that installs directly inside the rotating pinion gear in the gearbox. From this location, it detects and transmits high-resolution prognostic data to a fixed transceiver. The sensor is based on microelectromechanical systems (MEMS) technology and uses innovative circuit designs to capture high-bandwidth data and transmit it wirelessly from inside an operational helicopter transmission. With Ridgetop's advanced MEMS-based sensor, researchers have, for the first time, been able to extract high-resolution acoustic signatures wirelessly from sensors within the transmission that would otherwise be muffled by background gear noises. Ridgetop's innovative instrument will help researchers perform dynamic analysis of gear interaction and develop improved designs for gear components. In addition, data from this instrument can be used to validate new algorithms that detect and predict faults based on external acoustic signatures, for prognostic purposes. The result of this work will be an improvement in safety, performance, and cost for future generations of rotating components.

Wagoner, Robert↗

NASA NTRS1980

A new method of efficient heat transfer and storage at very high temperatures

A unique, high temperature (1000-2000 K) continuously operating capacitive heat exchanger system is described. The system transfers heat from a combustion or solar furnace to a working gas by means of a circulating high temperature molten refractory. A uniform aggregate of beads of a glass-like refractory is injected into the furnace volume. The aggregate is melted and piped to a heat exchanger where it is sprayed through a counter-flowing, high pressure working gas. The refractory droplets transfer their heat to the gas, undergoing a phase change into the solid bead state. The resulting high temperature gas is used to drive a suitable high efficiency heat engine. The solidified refractory beads are delivered back to the furnace and melted to continue the cycle. This approach avoids the important temperature limitations of conventional tube-type heat exchangers, giving rise to the potential of converting heat energy into useful work at considerably higher efficiencies than currently attainable and of storing energy at high thermodynamic potential.

Shaw, D.↗

NASA NTRS1980

Long wavelength PbSnTe lasers with CW operation above 77 K

Lead tin telluride diode lasers with emission wavelengths of 6 to 9 micrometers easily operate continuously at temperatures above 77K. These lasers have the Pb(1-y) Sn(y) TE/Pb(1-y) Te/Pb(1-y) Sn(y) Te/PbTe (substrate), (x y) double heterostructure. To prepare this structure by LPE, the growth temperature must be below 600 C to suppress diffusion of the tin during the epitaxial growth. When the heterojunctions are formed by the usual LPE method, the junction boundaries become irregular in the case for the lasers with wavelengths of over 10 micrometers at 77K. The mechanism by which the heterojunction boundaries become irregular is cleared and a new LPE method which prevents the irregularity is explained. The lasers prepared from the wafers grown by the new method have demonstrated CW operation at wavelengths longer than 10 micrometers above liquid nitrogen temperature.

Shinohara, K.↗

NASA NTRS2005

Beyond the Prototype: The Design Evolution of a Deployed AI System

Our previous experiences with deployed intelligent control agents for NASA advanced life support systems (Schreckenghost et al., 2002) inspired us to develop the Distributed Collaboration and Interaction (DCI) system to help humans and mostly-autonomous software agents work together. We discovered many unaddressed needs for human interaction with control agents that operate continuously over months to years to monitor and perform process control for regenerative life support systems. These systems recover usable water or air from the waste products created by biological systems over time. Through the DCI project, we have addressed the needs for interaction between humans and autonomous control systems. This paper describes the software engineering aspects of our experiences, first, in designing and developing a prototype of the DCI system, and later, in adjusting the implementation to make the leap from initial prototype to a system ready to be applied under varying circumstances to meet different needs. The details in the paper focus primarily on the second stage of development. The DCI system is currently deployed, operating 24/7, to assist humans to interact with an advanced Water Recovery System (WRS). In addition, we have demonstrated an application of DCI to support ground personnel in mission support roles.

Martin, C.↗

NASA NTRS2004

Beyond the Prototype: The Design Evolution of a Deployed AI System

Martin, Cheryl↗

DOE OSTI2023

Adaptive Cyber-Physical Resilience for Building Control Systems

The main goal of the project is to develop an AI-based process layer cybersecurity suite for detection, isolation and mitigation of cyber-attack effects on operation of building energy management systems (BEMS). The following constituent key technologies were developed under the program towards fulfilling the program objectives: (1) developed a high fidelity BEMS testbed for generation of training data and validation of developed technologies; (2) developed a physics informed ML based attack detection and localization module (ADL) capable of detecting high impact stealthy attacks (HISA - attacks causing 30% energy utilization but no immediate visible impact otherwise) with 98% accuracy; (3) developed a methodology to determine ’representative days’ to limit the data required for training; (4) developed a virtual sensing system that can reconstruct affected sensors with 10% error for the same HISA set; (5) developed a resilient model predictive control system that can continue operation of the BEMS without jeopardizing stability for the HISA set; and (6) integrated and deployed all the constituent modules and demonstrated the efficacy of the technology in real-time in a hardware in loop simulation.

42 ENGINEERING↗

NASA NTRS1994

Small satellite space operations

CTA Space Systems has played a premier role in the development of the 'lightsat' programs of the 80's and 90's. The high costs and development times associated with conventional LEO satellite design, fabrication, launch, and operations continue to motivate the development of new methodologies, techniques, and generally low cost and less stringently regulated satellites. These spacecraft employ low power 'lightsat' communications (versus TDRSS for NASA's LEO's) and typically fly missions with payload/experiment suites that can succeed, for example, without heavily redundant backup systems and large infrastructures of personnel and ground support systems. Such small yet adaptable satellites are also typified by their very short contract-to-launch times (often one to two years). This paper reflects several of the methodologies and perspectives of our successful involvement in these innovative programs and suggests how they might relieve NASA's mounting pressures to reduce the cost of both the spacecraft and their companion mission operations. It focuses on the use of adaptable, sufficiently powerful yet inexpensive PC-based ground systems for wide ranging user terminal (UT) applications and master control facilities for mission operations. These systems proved themselves in successfully controlling more than two dozen USAF, USN, and ARPA satellites at CTA/SS. UT versions have linked with both GEO and LEO satellites and functioned autonomously in relay roles often in remote parts of the world. LEO applications particularly illustrate the efficacy of these concepts since a user can easily mount a lightweight antenna, usually an omni or helix with light duty rotors and PC-based drivers. A few feet of coax connected to a small transceiver module (the size of a small PC) and a serial line to an associated PC establishes a communications link and together with the PC constitute a viable ground station. Applications included geomagnetic mapping; spaceborne solid state recorder validation; global store-and-forward data communications for both scientific and military purposes such as Desert Storm; UHF transponder services for both digital data and voice using a constellation; remote sensor monitoring of weather and oceanographic conditions; classified payloads; and UHF spectrum surveillance. Ground processing has been accomplished by automatic unattended or manual operation. Management of multiple assets highlights the relative ease with which two constellations totaling nine satellites were controlled from one system including constellation station keeping. Our experience in small end-to-end systems including concurrent design, development, and testing of the flight and operational ground systems offers low cost approaches to NASA scientific satellite operations of the 1990's.

Reiss, Keith↗

NASA NTRS2003

Medium Frequency Pseudo Noise Geological Radar

System and methods are disclosed for transmitting and receiving electromagnetic pulses through a geological formation. A preferably programmable transmitter having an all-digital portion in a preferred embodiment may be operated at frequencies below 1 MHz without loss of target resolution by transmitting and over sampling received long PN codes. A gated and stored portion of the received signal may be correlated with the PN code to determine distances of interfaces within the geological formation, such as the distance of a water interfaces from a wellbore. The received signal is oversampled preferably at rates such as five to fifty times as high as a carrier frequency. In one method of the invention, an oil well with multiple production zones may be kept in production by detecting an approaching water front in one of the production zones and shutting down that particular production zone thereby permitting the remaining production zones to continue operating.

G Dickey Arndt↗

NASA NTRS2005

Method for Controlling a Producing Zone of a Well in a Geological Formation

System and methods for transmitting and receiving electromagnetic pulses through a geological formation. A preferably programmable transmitter having an all-digital portion in a preferred embodiment may be operated at frequencies below 1 MHz without loss of target resolution by transmitting and over sampling received long PN codes. A gated and stored portion of the received signal may be correlated with the PN code to determine distances of interfaces within the geological formation, such as the distance of a water interfaces from a wellbore. The received signal is oversampled preferably at rates such as five to fifty times as high as a carrier frequency. In one method of the invention, an oil well with multiple production zones may be kept in production by detecting an approaching water front in one of the production zones and shutting down that particular production zone thereby permitting the remaining production zones to continue operating.

G Dickey Arndt↗

NASA NTRS2005

Method for controlling a producing zone of a well in a geological formation

Arndt, G. Dickey↗

NASA NTRS2012

The Chandra X-Ray Observatory: Progress Report and Highlights

Over the past 13 years, the Chandra X-ray Observatory's ability to provide high resolution X-ray images and spectra have established it as one of the most versatile and powerful tools for astrophysical research in the 21st century. Chandra explores the hot, high-energy regions of the universe, observing X-ray sources with fluxes spanning more than 10 orders of magnitude, from the X-ray brightest, Sco X-1, to the faintest sources in the Chandra Deep Field South survey. Thanks to its continuing operational life, the Chandra mission now also provides a long observing baseline which, in and of itself, is opening new research opportunities. Observations in the past few years alone have deepened our understanding of the co-evolution of supermassive black holes and galaxies, the details of black hole accretion, the nature of dark energy and dark matter, the details of supernovae and their progenitors, the interiors of neutron stars, the evolution of massive stars, and the high-energy environment of protoplanetary nebulae and the interaction of an exo-planet with its star. Here we update the technical status, highlight some of the scientific results, and very briefly discuss future prospects. We fully expect that the Observatory will continue to provide outstanding scientific results for many years to come.

Weisskopf, Martin C.↗

NASA NTRS2021

Adaptive-Sweep Algorithm for Spacecraft Carrier Acquisition and Tracking: System Analysis and Implementation

This paper presents an adaptive-sweep algorithm that can be used in conjunction with a Phased-Lock Loop to acquire and track the carrier of a Binary Phase-shift Keying signal with residual carrier. This algorithm is useful in proximity links where no Doppler pre-compensation is available at the transmitter, and allows the receiver to acquire the incoming carrier even if the experienced Doppler shift is several orders of magnitude larger than the PLL bandwidth. Other applications for this algorithm include Multiple Uplink per Antenna at the Deep Space Network, and generation of observables (Doppler shift, Doppler rate, range rate) for in-situ navigation purposes. This paper enhances a previously presented adaptive-sweep algorithm and its performance analysis in two fronts. First, the algorithm now uses the direction function to automatically estimate the required frequency jump to achieve PLL lock. This enables a fully adaptive-sweep scheme in which system implementer does not need to manually select thresholds. On the other hand, we study the system performance in the presence of Additive White Gaussian Noise and derive necessary conditions for the system to operate at low signal-to-noise conditions. This allows us to create design rules that specify all parameters of the algorithm given a set of system-level requirements. To test the performance of the proposed algorithm, we implement it in GNU Radio, an open-source Software-Defined Radio that interfaces with several commercial radio peripherals. We use this implementation to demonstrate carrier lock and quantify system performance under different noise conditions. We also test the algorithm using open-loop recordings of two downlinks between the Lunar Reconnaissance Orbiter and the Deep Space Network. We show that even after large frequency jumps (tens of kHz), the proposed system is able to rapidly reacquire the carrier and continue operation.

Divsalar, Dariush↗

DOE OSTI2022

Continuous recovery of high-purity Kraft lignin from black liquor via simultaneous, liquid-phase acidification and purification

Here, a key advantage of the Sequential Liquid-Lignin Recovery and Purification (SLRP) process for the recovery of lignin from Kraft black liquor is the precipitation of a solvated, “liquid-lignin” phase (vs. the typical solid) during the CO 2 acidification step. Here, we have discovered that this lignin can also be maintained in a solvated state during the H 2 SO 4 acidification step if aqueous acetic acid from the Aqueous Lignin Purification with Hot Agents (ALPHA) process is incorporated into the H 2 SO 4 solution. As the liquid-lignin is converted from its salt form at pH = 9.5 to its acid form at pH = 2.5, the lignin initially solvated with water becomes solvated and thus liquefied with the organic–water solution. Maintaining the lignin in a solvated liquid state has two advantages: (1) the entire SLRP + ALPHA process, from starting black liquor to final lignin product, can be operated continuously; and (2) mass transfer of metals impurities out of the liquid-lignin phase is significantly enhanced, resulting in both a cleaner Kraft lignin product (~2000 ppm Na and 0.5-1.0 % ash) and reduced water washing.

09 BIOMASS FUELS↗

NASA NTRS2008

Performance Evaluation of the Prototype Model NEXT Ion Thruster

The performance testing results of the first prototype model NEXT ion engine, PM1, are presented. The NEXT program has developed the next generation ion propulsion system to enhance and enable Discovery, New Frontiers, and Flagship-type NASA missions. The PM1 thruster exhibits operational behavior consistent with its predecessors, the engineering model thrusters, with substantial mass savings, enhanced thermal margins, and design improvements for environmental testing compliance. The dry mass of PM1 is 12.7 kg. Modifications made in the thruster design have resulted in improved performance and operating margins, as anticipated. PM1 beginning-of-life performance satisfies all of the electric propulsion thruster mission-derived technical requirements. It demonstrates a wide range of throttleability by processing input power levels from 0.5 to 6.9 kW. At 6.9 kW, the PM1 thruster demonstrates specific impulse of 4190 s, 237 mN of thrust, and a thrust efficiency of 0.71. The flat beam profile, flatness parameters vary from 0.66 at low-power to 0.88 at full-power, and advanced ion optics reduce localized accelerator grid erosion and increases margins for electron backstreaming, impingement-limited voltage, and screen grid ion transparency. The thruster throughput capability is predicted to exceed 750 kg of xenon, an equivalent of 36,500 hr of continuous operation at the full-power operating condition.

Herman, Daniel A.↗