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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Microstructural development in DED stainless steels: applying welding models to elucidate the impact of processing and alloy composition

Austenitic stainless steel microstructures produced by directed energy deposition (DED)are analogous to those developed during welding, particularly high energy density welding. To better understand microstructural development during DED, theories of microstructural evolution,which have been established to contextualize weld microstructures, are applied in this study to microstructural development in DED austenitic stainless steels. Phenomenological welding models that describe the development of oxide inclusions, compositional microsegregation, ferrite,matrix austenite grains, and dislocation substructures are utilized to clarify microstructural evolution during deposition of austenitic stainless steels. Two different alloys, 304L and 316L, arecompared to demonstrate the broad applicability of this framework for understanding microstmctural development during the DED process. Despite differences in grain morphology and solidification mode for these two alloys (which can be attributed to compositional differences),similar tensile properties are achieved. It is the fine-scale compositional segregation and dislocation structures that ultimately determine the strength of these materials. The evolution of microsegregation and dislocation structures is shown to be dependent on the rapid solidification and thermomechanical history of the DED processing method and not the composition of the starting material.

36 MATERIALS SCIENCE↗
NASA NTRS1978

An investigation for the development of an integrated optical data preprocessor

The successful fabrication and demonstration of an integrated optical circuit designed to perform a parallel processing operation by utilizing holographic subtraction to simultaneously compare N analog signal voltages with N predetermined reference voltages is summarized. The device alleviates transmission, storage and processing loads of satellite data systems by performing, at the sensor site, some preprocessing of data taken by remote sensors. Major accomplishments in the fabrication of integrated optics components include: (1) fabrication of the first LiNbO3 waveguide geodesic lens; (2) development of techniques for polishing TIR mirrors on LiNbO3 waveguides; (3) fabrication of high efficiency metal-over-photoresist gratings for waveguide beam splitters; (4) demonstration of high S/N holographic subtraction using waveguide holograms; and (5) development of alignment techniques for fabrication of integrated optics circuits. Important developments made in integrated optics are the discovery and suggested use of holographic self-subtraction in LiNbO3, development of a mathematical description of the operating modes of the preprocessor, and the development of theories for diffraction efficiency and beam quality of two dimensional beam defined gratings.

Verber, C. M.↗
DOE OSTI2023

On Distribution Grid Optimal Power Flow Development and Integration

Due to changes in electric distribution grid operation, new operation regimes have been recommended. Distribution grid optimal power flow (DOPF) has received tremendous attention in the research community, yet it has not been fully adopted across the utility industry. Our paper recognizes this problem and suggests a development and integration procedure for DOPF. We propose development of DOPF as a three step procedure of 1) processing the grid, 2) obtaining a tractable solution, and 3) implementing multiple solution algorithms and benchmarking them to improve application reliability. For the integration of DOPF, we demonstrate how a DOPF federate may be developed that can be integrated in a co-simulation environment to mimic the real-world conditions and hence improve its practicality to be deployed in the field. To demonstrate the efficacy of the proposed methods, tests on IEEE 123 bus system are performed where the usage of tractable formulation in DOPF algorithm development and its comparison to the benchmark solution are demonstrated.

Hanif, Sarmad↗
DOE OSTI2025

Quantum Information for Fusion Energy Sciences (Final Technical Report)

The simulation of plasma dynamics is a critical area of Fusion Energy Sciences (FES) due to it’s usefulness in predicting, controlling, and confining plasmas in the context of potential fusion reactors. The simulation of plasmas is a computationally difficult problem in both classical and quantum physics, motivating investigation into the potential of quantum computers to simulate these systems. This project took several concrete steps towards this goal by developing tools for improving the control, characterization, and calibration of quantum gates on a superconducting quantum computer, developing error suppression and mitigation tools to reduce errors on the quantum computer, and utilizing these advancements to simulate reduced models of plasma dynamics on the quantum computer. In order to efficiently simulate plasma physics, an optimal control method which synthesizes, directly at the pulse level, any quantum gate on qubit and qutrit systems was developed. Using four superconducting transmon quantum processors at Rigetti and LLNL, it was demonstrated that any arbitrary quantum gate on qubits and qutrits could be implemented with high fidelity, leading to a significantly reduced length of a gate sequence. A problem of interest in FES is the nonlinear optical process of laser pulse compression within a plasma. Since quantum physics is linear, simulating nonlinear operations is not naturally feasible on a quantum computer, however it is possible to simulated a quantized version of the nonlinear process. A quantization approach to convert nonlinear wave-wave interaction problems to Hamiltonian simulation problems was developed and demonstrated using two qubits on a Rigetti device. In this experiment, a number of error suppression and mitigation techniques were investigated to determine how best to utilize the finite quantum resources. This study provides an example of how plasma problems may be solved on near-term, noisy quantum computing platforms and identified a promising set of techniques. Building on the insights of these experiments, the investigation turned to linear electron-plasma wave physics. A connection was identified between a local one-dimensional lattice spin model and linear wave phenomena, allowing a plasma physics problem to be efficiently mapped to the quantum computer. In this framework, reflection and transmission of plasma waves at a sharp boundary was studied, as well as the propagation of waves through an inhomogeneous plasma medium. In addition to the suite of error suppression and mitigation techniques developed, this experiment introduced the use of a digital-analog gate scheme designed to efficiently simulate the plasma Hamiltonian. With hardware available at the conclusion of the project, simulation at the scale of 9 qubits and 15 timesteps (60 entangling layers) was achieved.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2003

[Technology Development for X-Ray Reflection for the Constellation-X Reflection Grating Spectrometer (RGS)]

This Grant covers MIT support for the technology development of x-ray reflection gratings for the Constellation-X Reflection Grating Spectrometer (RGS). Since the start of the Grant MIT has extended its previously-developed patterning and super-smooth, blazed grating fabrication technology to ten-times smaller grating periods and ten-times larger blaze angles to demonstrate feasibility and performance in the off-plane grating geometry. In the past year we successfully developed several nanoimprint grating replication methods that achieved very high fidelity replication of master silicon gratings. Grating geometry on the nano and macro scales were faithfully replicated, demonstrating the viability of the process for manufacturing the thousands of gratings required for the RGS. We also successfully developed an improved metrology truss for holding test grating substrates during metrology. The flatness goal of grating substrates is under 500 nm. In the past, grating holders would cause non-repeatable distortion of >> 500 nm to the substrates due to friction and gravity sag. The new holder has a repeatability of under 50 nm which is adequate for the proposed RGS grating substrates.

Schattenburg, Mark L.↗
NASA NTRS1981

A Module Experimental Process System Development Unit (MEPSDU)

Subsequent to the design review, a series of tests was conducted on simulated modules to demonstrate that all environmental specifications (wind loading, hailstone impact, thermal cycling, and humidity cycling) are satisfied by the design. All tests, except hailstone impact, were successfully completed. The assembly sequence was simplified by virtue of eliminating the frame components and assembly steps. Performance was improved by reducing the module edge border required to accommodate the frame of the preliminary design module. An ultrasonic rolling spot bonding technique was selected for use in the machine to perform the aluminum interconnect to cell metallization electrical joints required in the MEPSDU module configuration. This selection was based on extensive experimental tests and economic analyses.

Source record↗
NASA NTRS1978

Development of pulsed processes for the manufacture of solar cells

The results of a 1-year program to develop the processes required for low-energy ion implantation for the automated production of silicon solar cells are described. The program included: (1) demonstrating state-of-the-art ion implantation equipment and designing an automated ion implanter, (2) making efforts to improve the performance of ion-implanted solar cells to 16.5 percent AM1, (3) developing a model of the pulse annealing process used in solar cell production, and (4) preparing an economic analysis of the process costs of ion implantation.

Minnucci, J. A.↗
DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗
DOE OSTI2021

An Open-Source Virtual Testbed for a Real Net-Zero Energy Community

Net zero energy communities (NZECs) are critical to ensure sustainability and resilience of modernized power systems. System modeling helps overcome technical challenges in designing and operating NZECs. In this paper, we present the modeling work based on a real NZEC. Two sets of models are developed: higher-fidelity physics-based models considering the interaction between subsystems of the studied NZEC and capturing fast-dynamics; and lower-fidelity data-driven models requiring less resource to establish and/or run. All models are validated against measurements from this real NZEC. In addition, we create a simulation framework which streamlines the processes for simulation and thus allows using developed models to form a virtual testbed. To demonstrate the usage of the virtual testbed, a case study is conducted where a building-to-grid integration control is evaluated via simulation. The evaluation results suggest that the tested control significantly smooths the power draw of the studied community and doesn’t sacrifice the thermal comfort to a great extent.

Huang, Sen↗
DOE OSTI2026

Recent progress in atomic-scale controlled plasma processing

Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.

Ishikawa, Kenji [Nagoya Univ. (Japan)] (ORCID:0000↗
DOE OSTI2021

Tunable Atomic Layer Deposition into Ultra-High-Aspect-Ratio (>60000:1) Aerogel Monoliths Enabled by Transport Modeling

Atomic layer deposition (ALD) modification of ultra-high-aspect-ratio structures (>10,000:1) is a powerful platform with applications in catalysis, filtration, and energy conversion. However, the deposition of conformal and tunable ALD coatings at these aspect ratios remains challenging, resulting in empirical tradeoffs between precursor utilization and reaction time. Here, we demonstrate tunable control of the ALD infiltration depth into an aerogel monolith (AM) and develop a reaction-diffusion model to accurately describe the coating process. Specifically, we investigate the ALD exposure time and precursor dose needed to conformally coat a silica AM with pore sizes of ~20 nm, a monolith thickness of ~2.5 mm, and aspect ratios exceeding 60,000:1. We demonstrate complete infiltration into the AM, which is quantified by elemental mapping. A reaction-diffusion model is developed, which accounts for multiple doses and precursor depletion in the ALD chamber during an exposure step. The experimentally validated model enables the prediction and tuning of infiltration depth into a tortuous, high-aspect-ratio structure such as an AM, allowing for the synthesis of rationally designed material architectures. Additionally, the model allows for co-optimization of the total deposition time and percentage of unreacted precursor, which are important for the manufacturability and sustainability of ALD processing. Lastly, we demonstrate that ultra-thin ALD Al 2 O 3 coatings can be used to stabilize silica AMs against structural degradation under high-temperature annealing conditions (700-800 °C), by limiting changes in surface area and monolith volume. As a result, this improved high-temperature stability has implications for numerous aerogel applications, including catalysis and thermal insulation.

14 SOLAR ENERGY↗
NASA NTRSDate not supplied

Development of Subsonic Single Aft Engine (SUSAN) Attritable Research Vehicle (SARV) Wing Structure

This paper introduces a high-level overview of the design and development of the SUbsonic Single Aft eNgine (SUSAN) Attritable Research Vehicle (SARV) wing structure. Unique design considerations were made for the structural layout of the wing to include storage for batteries, distributed electric engines, and the requirement for the wing to be shippable in a cargo box. The wing structure development process will be discussed including the wing internal structure design evolution, the fabrication of the manufacturing demonstration vehicle, wing outer mold line design, integration of wing internal structure and wing skins, and finally integration of the wing with the fuselage structure. Additionally, the development of the wing skin design will be discussed while highlighting the wing skin manufacturing demonstration panels as well as composite testing for material characterization purposes.

wing structure↗
DOE OSTI2025

Assessment of Microstructure Prediction Capabilities for Powder Bed Fusion Stainless Steel 316

The Advanced Materials and Manufacturing Technologies program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. However, the characteristic process-structure-property relationships of additive manufacturing (AM) materials pose challenges for the qualification and certification of AM nuclear components. In particular, component-scale variations in microstructure and properties can be driven by localized changes in melt pool dynamics due to how process parameters interact with different part geometries. Computational modeling tools can play a crucial role in predicting and controlling this variability. This report presents final results on process modeling tools designed to predict microstructure variability in additively manufactured stainless steel 316 parts. It details the software packages and physical modeling approaches employed to simulate an AM component within an automated process modeling workflow. Results are demonstrated through comparisons between predicted microstructures and experimental measurements across various representative processing conditions. The report concludes by discussing identified challenges and future opportunities for connecting the developed simulation workflow with mechanics simulations for prediction of part performance.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Probabilistic simulation of long term behavior in polymer matrix composites

A methodology to compute cumulative probability distribution functions (CDF) of fatigue life for different ratios, r of applied stress to the laminate strength based on first ply failure criteria has been developed and demonstrated. Degradation effects due to long term environmental exposure and mechanical cyclic loads are considered in the simulation process. A unified time-stress dependent multi-factor interaction equation model developed at NASA Lewis Research Center has been used to account for the degradation/aging of material properties due to cyclic loads. Fast probability integration method is used to perform probabilistic simulation of uncertainties. Sensitivity of fatigue life reliability to uncertainties in the primitive random variables are computed and their significance in the reliability based design for maximum life is discussed. The results show that the graphite/epoxy (0/+45/90) deg laminate with ply thickness 0.125 in. has 500,000 cycles life for applied stress to laminate strength ratio of 0.6 and a reliability of 0.999. Also, the fatigue life reliability has been found to be most sensitive to the ply thickness and matrix tensile strength. Tighter quality controls must therefore be enforced on ply thickness and matrix strength in order to achieve high reliability of the structure.

Shah, A. R.↗
DOE OSTI2022

Experimental validation of multiphysics model simulations of the thermal response of a cement clinker rotary kiln at laboratory scale

Abstract An increasing demand for buildings, transportation systems and civil infrastructure development has driven expansion of cement consumption world‐wide, producing a significant increase in related global energy demand. With approximately 7% of the world‐wide industrial energy consumption (10.7 exajoules [EJ]), the cement industry is the third most energy intensive industrial processes and a key component for concrete, the most consumed composite material in the global construction industry. In cement manufacturing, the cement kiln accounts for most of the energy consumption in the production process. As the heart of a cement plant, the cement kiln is where the kiln feed primarily containing calcium oxide (CaO), silica (SiO 2 ), alumina (Al 2 O 3 ), and iron (Fe 2 O 3 ) are thermally and chemically transformed into clinker minerals. The presented work developed a multiphysics model, designed and built a laboratory‐scale rotary cement clinker kiln, and produced cement clinker at laboratory‐scale. The model was developed to study the interaction between the various thermal, fluid dynamic and chemical interactions involved in the sintering process used to form Portland cement clinker in an effort to reduce energy use. The analytical model was validated through experimental testing using a unique laboratory‐scale rotary cement kiln developed during the investigation. Also demonstrated was the feasibility of producing clinker at laboratory scale. This modeling and lab scale tests were designed to better understand the clinker sintering process so that operational and quality decisions can be made to optimize energy consumption without compromising cement clinker quality. The computational fluid dynamics modeling was developed in COMSOL Multiphysics 6.0. The characteristics of the combustion fluid flow, concentration of species, temperature and heat transfer were studied for a turbulent flow of methane (CH 4 ) gas and oxygen (O 2 ). Theory suggests that heat transfer impacts the cement production process but the multiphysics model more accurately describes the convection, conduction, and radiant heat transfer in the kilning process and thus allows for a better understanding of the energy exchange driving the chemical reactions that produce Portland cement. Clinker minerals were formed because of appropriate burning conditions implemented during experimental model validation.

Tabares, Juan David↗
DOE OSTI2020

Current Status of the Synroc Waste Treatment Facility - 20263

Construction of the Synroc Waste Treatment Facility is well underway at ANSTO. This plant has been designed to treat intermediate level liquid waste arising from the production of Mo-99 within the newly constructed ANSTO Nuclear Medicine (ANM) precinct [1]. The facility utilises ANSTO Synroc technology that has been tailored to the chemical, physical, and radiological properties of the waste. The result is a highly durable wasteform with a significant reduction in the final volume of the treated waste. This paper presents the construction status of the Synroc Waste Treatment Facility and the status of the associated technology maturation plan. Construction of the building is scheduled for completion in late 2020 followed by process installation and commissioning. A key component of the technology maturation plan has been the construction of an Inactive Engineering Demonstrator [2]. This has aided in the mitigation of risks with respect to technology selection, process integration, and process nuclearisation. Furthermore, the demonstration facility has provided an environment for the design and development of the instrumentation and control philosophy resulting in a seamlessly integrated plant control system. Successful demonstration of the technology by the inactive engineering demonstrator has significantly reduced the associated risks. Details of the Synroc Waste Treatment Facility project progress will also be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Design and Use of a Penetrating Deposition Nozzle for Z-Pinning Additive Manufacturing

Fused Filament Fabrication (FFF) involves depositing material layer-by-layer to create athree-dimensional object. This method often demonstrates high mechanical anisotropy in theprinted structure, leading to a drop in the material strength of the part when comparing structuresalong the deposition plane (X/Y-Axis) versus across layers in the build direction (Z-Axis). Initialefforts to improve anisotropy led to the development of the Z-Pinning process, where continuouspins are deposited across layers in the Z-Axis. Z-pinning has demonstrated significant gains intoughness and inter-layer strength, particularly in fiber-reinforced materials. However, thisprocess can also create flaws in the structure that increase in severity and frequency as the pinsgrow in length and diameter. To mitigate this, a penetrating nozzle has been developed thatextends a fine-tipped extrusion nozzle deep into the pin cavity and simultaneously extrudesmaterial as it retracts. This study investigates the printability of the penetrating nozzle for simplegeometries and evaluates the resulting Z-pinning mesostructure. As a result of this study, theprototype penetrating nozzle design was analyzed and built. Through a pressure driven flowanalysis it was determined that the penetrating nozzle extruder can not only flow extrudefilament. After a transient thermal simulation it was found that after a pause of 15 secondsresume printing with no drop in heat at nozzle exit.

Bales, Brenin↗
NASA NTRS2018

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100hrs to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne (AR) is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗