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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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Determination of Location-Specific Solidification Cracking Susceptibility for a Mixed Dissimilar Alloy Processed by Wire-Arc Additive Manufacturing
Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy mixture of 26 wt.% P91 and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks in the FCC matrix, which increased in length along with the enrichment of Nb (~27 to 56 wt.%) and Cu (~87 wt.%) in the middle and top regions. DICTRA simulations to model location-specific solidification cracking susceptibility showed that the top region with the highest cooling rate (270 K/s) has the highest solidification cracking susceptibility in comparison with the middle and bottom regions. This is in good agreement with the experimentally observed varying crack length. From Scheil simulations, it was deduced that enrichment of Nb and Cu affected the solidification range as high as ~77%, in comparison with the matrix composition. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.
Increasing the compression pressure in an engine by using a long intake pipe
During some tests of a one-cylinder engine, using gas oil (diesel engine oil, specific gravity 0.86 at 60 F) with solid injection and compression ignition, it was found to be necessary to increase either the jacket water temperature or the compression pressure in order to start the engine. It was found that a sufficient increase in compression pressure could be obtained simply by attaching a long pipe to the inlet flange of the cylinder. However, since no data were available giving the values of the increase in compression pressure that might be expected from such a step-up, an investigation was made covering some engine speeds between 500 r.p.m. and 1800 r.p.m. The data obtained are included here in the form of curves. Although this data is not strictly applicable to another engine, it should give indications of what might be expected with such a set-up on an engine operating at similar speeds. The engine used was a single cylinder Liberty, 5-inch bore and 7-inch stroke, having standard cylinder, cams, valves, and valve timing and operating on a four-stroke cycle.
Method for thermally spraying crack-free mullite coatings on ceramic-based substrates
A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.
Method for thermally spraying crack-free mullite coatings on ceramic-based substrates
A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.
Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap
Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.
Some Effects of Rapid Inlet Pressure Oscillation on the Operation of a Turbojet Engine
A program was conducted in an altitude facility at the NACA Lewis laboratory to investigate the effects of rapid inlet pressure oscillations on the operation of a current turbo jet engine. These pressure oscillations were approximately sinusoidal in form and were generated to cover a frequency range of 2 to 75 cycles per second and an amplitude range of 10 to 70 percent of the free-stream total pressure. As the oscillation progressed through the compressor, the amplitude was attenuated considerably and a relatively large phase shift (lag) occurred. Engine stall limits obtained during pressure oscillations differed from quasi-steady-state stall limits as defined by over-all compressor pressure ratio.
Automated Antenna Design with Evolutionary Algorithms
Current methods of designing and optimizing antennas by hand are time and labor intensive, and limit complexity. Evolutionary design techniques can overcome these limitations by searching the design space and automatically finding effective solutions. In recent years, evolutionary algorithms have shown great promise in finding practical solutions in large, poorly understood design spaces. In particular, spacecraft antenna design has proven tractable to evolutionary design techniques. Researchers have been investigating evolutionary antenna design and optimization since the early 1990s, and the field has grown in recent years as computer speed has increased and electromagnetic simulators have improved. Two requirements-compliant antennas, one for ST5 and another for TDRS-C, have been automatically designed by evolutionary algorithms. The ST5 antenna is slated to fly this year, and a TDRS-C phased array element has been fabricated and tested. Such automated evolutionary design is enabled by medium-to-high quality simulators and fast modern computers to evaluate computer-generated designs. Evolutionary algorithms automate cut-and-try engineering, substituting automated search though millions of potential designs for intelligent search by engineers through a much smaller number of designs. For evolutionary design, the engineer chooses the evolutionary technique, parameters and the basic form of the antenna, e.g., single wire for ST5 and crossed-element Yagi for TDRS-C. Evolutionary algorithms then search for optimal configurations in the space defined by the engineer. NASA's Space Technology 5 (ST5) mission will launch three small spacecraft to test innovative concepts and technologies. Advanced evolutionary algorithms were used to automatically design antennas for ST5. The combination of wide beamwidth for a circularly-polarized wave and wide impedance bandwidth made for a challenging antenna design problem. From past experience in designing wire antennas, we chose to constrain the evolutionary design to a monopole wire antenna. The results of the runs produced requirements-compliant antennas that were subsequently fabricated and tested. The evolved antenna has a number of advantages with regard to power consumption, fabrication time and complexity, and performance. Lower power requirements result from achieving high gain across a wider range of elevation angles, thus allowing a broader range of angles over which maximum data throughput can be achieved. Since the evolved antenna does not require a phasing circuit, less design and fabrication work is required. In terms of overall work, the evolved antenna required approximately three person-months to design and fabricate whereas the conventional antenna required about five. Furthermore, when the mission was modified and new orbital parameters selected, a redesign of the antenna to new requirements was required. The evolutionary system was rapidly modified and a new antenna evolved in a few weeks. The evolved antenna was shown to be compliant to the ST5 mission requirements. It has an unusual organic looking structure, one that expert antenna designers would not likely produce. This antenna has been tested, baselined and is scheduled to fly this year. In addition to the ST5 antenna, our laboratory has evolved an S-band phased array antenna element design that meets the requirements for NASA's TDRS-C communications satellite scheduled for launch early next decade. A combination of fairly broad bandwidth, high efficiency and circular polarization at high gain made for another challenging design problem. We chose to constrain the evolutionary design to a crossed-element Yagi antenna. The specification called for two types of elements, one for receive only and one for transmit/receive. We were able to evolve a single element design that meets both specifications thereby simplifying the antenna and reducing testing and integration costs. The highest performance antenna found using a getic algorithm and stochastic hill-climbing has been fabricated and tested. Laboratory results correspond well with simulation. Aerospace component design is an expensive and important step in space development. Evolutionary design can make a significant contribution wherever sufficiently fast, accurate and capable software simulators are available. We have demonstrated successful real-world design in the spacecraft antenna domain; and there is good reason to believe that these results could be replicated in other design spaces.
Morphological–Electrical Property Relation in Cu(In,Ga)(S,Se) 2 Solar Cells: Significance of Crystal Grain Growth and Band Grading by Potassium Treatment
Abstract Solution‐processed Cu(In,Ga)(S,Se) 2 (CIGS) has a great potential for the production of large‐area photovoltaic devices at low cost. However, CIGS solar cells processed from solution exhibit relatively lower performance compared to vacuum‐processed devices because of a lack of proper composition distribution, which is mainly instigated by the limited Se uptake during chalcogenization. In this work, a unique potassium treatment method is utilized to improve the selenium uptake judiciously, enhancing grain sizes and forming a wider bandgap minimum region. Careful engineering of the bandgap grading structure also results in an enlarged space charge region, which is favorable for electron–hole separation and efficient charge carrier collection. Besides, this device processing approach has led to a linearly increasing electron diffusion length and carrier lifetime with increasing the grain size of the CIGS film, which is a critical achievement for enhancing photocurrent yield. Overall, 15% of power conversion efficiency is achieved in solar cells processed from environmentally benign solutions. This approach offers critical insights for precise device design and processing rules for solution‐processed CIGS solar cells.
Giant low-field magnetocaloric effect and refrigerant capacity in reduced dimensionality EuTiO 3 multiferroics
Engineering magnetic materials into a thin film form while preserving its excellent magnetocaloric response is essential in the development of miniature magnetic coolers. We demonstrate how this can be achieved in the case of EuTiO 3 - an emerging multiferroic material. Unlike conventional cases where reduced dimensionality considerably decreased the magnetic entropy change (ΔS M ) and hence the refrigerant capacity (RC), we show the large low-field enhancements of ΔS M and RC in a ~100 nm thick nanocrystalline EuTiO 3 film (ΔS M ~ 24 J kg -1 K -1 and RC = 152 J kg -1 for μ 0 ΔH = 2T) relative to its single crystal counterpart (ΔS M ~ 17 J kg -1 K -1 and RC ~ 107 J kg -1 for μ 0 ΔH = 2T). The nanocrystalline EuTiO 3 film is an excellent candidate for cryogenic magnetic refrigeration. From our study, a new approach for improving both MCE and RC in magnetic nanomaterials is proposed, which will stimulate further research on magnetocaloric thin films and related cooling devices.
N -Terminal Octylated Peptoid Hydrogels as 3D-Printable Cell Scaffolds and Proteolytically Robust Cargo Depots
Supramolecular hydrogels that mimic the extracellular matrix (ECM) represent promising materials for tissue engineering and drug delivery. However, conventional hydrogels formed via the self-assembly of natural or synthetic building blocks often face a trade-off between biological functionality and biochemical stability, limiting their utility in long-term or protease-rich environments. Peptoids, a class of peptide-inspired, sequence-defined polymers, offer a compelling alternative due to their exceptional proteolytic resistance and bioactivity. Despite this potential, the development of supramolecular peptoid hydrogels has been hindered by the absence of backbone hydrogen bond donors, which limits long-range ordering necessary for efficient hydrogel formation. This work describes a short peptoid functionalized at the N-terminus with an octyl chain that readily self-assembles into hydrogels. Hydrophobic interactions among pendant octyl groups promote directional peptoid packing into highly ordered nanosheets, which interconnect to form a porous hydrogel network. These hydrogels exhibit tunable viscoelasticity, shear-thinning, and self-healing properties, enabling their use as inks for extrusion-based 3D printing. They support NIH-3T3 fibroblast adhesion, spreading, and proliferation, maintaining greater than 95% cell viability over 4 days. Moreover, the hydrogels retain their macroscopic integrity under protease-rich conditions, enabling sustained cargo release and uniform cellular uptake. Together, this study demonstrates a class of supramolecular peptoid hydrogelators that integrate biocompatibility, 3D printability, and proteolytic stability, providing a versatile platform for ECMmimetic scaffolds in regenerative medicine and long-term therapeutic delivery.
Stretchable electrochemical energy storage devices
The increasingly intimate contact between electronics and the human body necessitates the development of stretchable energy storage devices that can conform and adapt to the skin. Therefore, the development of stretchable batteries and supercapacitors has received significant attention in recent years. This review provides an overview of the general operating principles of batteries and supercapacitors and the requirements to make these devices stretchable. The following sections provide an in-depth analysis of different strategies to convert the conventionally rigid electrochemical energy storage materials into stretchable form factors. Namely, the strategies of strain engineering, rigid island geometry, fiber-like geometry, and intrinsic stretchability are discussed. A wide range of materials are covered for each strategy, including polymers, metals, and ceramics. By comparing the achieved electrochemical performance and strain capability of these different materials strategies, we allow for a side-by-side comparison of the most promising strategies for enabling stretchable electrochemical energy storage. The final section consists of an outlook for future developments and challenges for stretchable supercapacitors and batteries.
Role of glucuronoxylomannan and steryl glucosides in protecting against cryptococcosis
The development of vaccines for fungal diseases, including cryptococcosis, is an emergent line of research and development. In previous studies, we showed that a Cryptococcus mutant lacking the SGL1 gene (∆sgl1) accumulates certain glycolipids called steryl glucosides (SGs) on the fungal capsule, promoting an effective immunostimulation that totally protects the host from a secondary cryptococcal infection. However, this protection is lost when the cryptococcal capsule is absent in the ∆sgl1 background. The cryptococcal capsule is mainly composed of glucuronoxylomannan (GXM), a polysaccharide microfiber consisting of glucuronic acid, xylose, and mannose linked by glycosidic bonds forming specific triads. In this study, we engineered cells to lack each of the GXM components and tested the effect of these deletions on protection under the condition of SG accumulation. We found that glucuronic acid and xylose are required for protection, and their absence abrogates the production of IFNγ and IL-17A by γδ T cells, which are necessary stimulants for the protective phenotype of the ∆sgl1. We analyzed the structure of the GXM microfibers and found that although the deletion of SGL1 only slightly affects the size and distribution of these microfibers, it significantly changes the ratio of mannose to other components. In conclusion, this study identifies the structural modifications that the deletion of SGL1 and the consequent accumulation of SGs impart to the GXM structure of C. neoformans. This provides significant insights into the protective mechanisms mediated by SG accumulation on the capsule, with important implications for the future development of an efficacious cryptococcal vaccine.
Research in the conversion of various forms of energy by unconventional techniques Status report
Thermoelectric materials engineering, plasma physics, and electrochemistry for direct energy conversion systems
Considerations from engineering psychology
Display media development and implementation from engineering psychology viewpoint for information transfer in form compatible to sensory-perceptual capabilities
Telemetry remote modules
A fully operational engineering telemetry remote module is reported that forms the basis for a decentralized telemetry system which employs small low powered modules capable of distributing the multiplexer input gates around a spacecraft. The module operates mainly as a harness reducer, allowing data to be transmitted back to a central control core for inclusion in the telemetry bit stream. Each unit is capable of accepting 32 data points in various combinations.
Hot corrosion of TD nickel and TD nickel chromium in a high velocity gas stream.
Results of cyclical tests of TD nickel (2% thoria-dispersed nickel) and TD nickel chromium (2% thoria-dispersed nickel-20% chromium alloy) 1.5 mm (60 mil) sheet specimens for susceptibility to hot corrosion in a Mach 0.5 gas stream of Jet A-1 fuel combustion products containing 2 ppm sea salt. Tests as long as 500 one-hour cycles between room temperature and specimen hot zone temperatures of 899 C (1650 F), 982 C (1800 F), and 1149 C (2100 F) were performed. Evidence of hot corrosion was found for both materials in the 899 C (1650 F) and 982 C (1800 F) tests, but not at 1149 C (2100 F). It was concluded that because of high metal thickness losses neither alloy in sheet form is suitable for long-time engine application in a hot corrosion environment at temperatures of 982 C (1800 F) or above.
Longitudinal handling qualities during approach and landing of a powered lift STOL aircraft
Longitudinal handling qualities evaluations were conducted on the Ames Research Center Flight Simulator for Advanced Aircraft (FSAA) for the approach and landing tasks of a powered lift STOL research aircraft. The test vehicle was a C-8A aircraft modified with a new wing incorporating internal blowing over an augmentor flap. The investigation included: (1) use of various flight path and airspeed control techniques for the basic vehicle; (2) assessment of stability and command augmentation schemes for pitch attitude and airspeed control; (3) determination of the influence of longitudinal and vertical force coupling for the power control; (4) determination of the influence of pitch axis coupling with the thrust vector control; and (5) evaluations of the contribution of stability and command augmentation to recovery from a single engine failure. Results are presented in the form of pilot ratings and commentary substantiated by landing approach time histories.