SEARCH · Engineering Papers

Results for “stacking engineering”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 487 records · Page 27

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Electrochemical Control of the Ultrafast Lattice Response of a Layered Semimetal

The unique layer-stacking in two-dimensional (2D) van der Waals materials facilitates the formation of nearly degenerate phases of matter and opens novel routes for the design of low-power, reconfigurable functional materials. Electrochemical ion intercalation between stacked layers offers a promising approach to stabilize bulk metastable phases and to explore the effects of extreme carrier doping and strain. However, in situ characterization methods to study the structural evolution and dynamical functional properties of these intercalated materials remains limited. Here a novel experimental platform is presented capable of simultaneously performing electrochemical lithium-ion intercalation and multimodal ultrafast characterization of the lattice using both electron diffraction and nonlinear optical techniques. Using the layered semimetal WTe 2 as a model system, the interlayer shear phonon mode that modulates stacking between 2Dlayers is probed, showing that small amounts of lithiation enhance the amplitude and lifetime of the phonon, contrary to expectations. This results from the dynamically fluctuating and anharmonic structure between nearly degenerate phases at room temperature, which can be stabilized by electronic carriers accompanying the inserted lithium ions. At high lithiation, the T d ’ structure emerges and quenches the phonon response. This work defines new approaches for using electrochemistry to engineer the dynamic structure of 2D materials.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Functional composites by programming entropy-driven nanosheet growth

Here, nanomaterials must be systematically designed to be technologically viable. Driven by optimizing intermolecular interactions, current designs are too rigid to plug in new chemical functionalities and cannot mitigate condition differences during integration. Despite extensive optimization of building blocks and treatments, accessing nanostructures with the required feature sizes and chemistries is difficult. Programming their growth across the nano-to-macro hierarchy also remains challenging, if not impossible. To address these limitations, we should shift to entropy-driven assemblies to gain design flexibility, as seen in high-entropy alloys, and program nanomaterial growth to kinetically match target feature sizes to the mobility of the system during processing. In tis report, following a micro-then-nano growth sequence in ternary composite blends composed of block-copolymer-based supramolecules, small molecules and nanoparticles, we successfully fabricate high-performance barrier materials composed of more than 200 stacked nanosheets (125 nm sheet thickness) with a defect density less than 0.056 µm -2 and about 98% efficiency in controlling the defect type. Contrary to common perception, polymer-chain entanglements are advantageous to realize long-range order, accelerate the fabrication process (<30 min) and satisfy specific requirements to advance multilayered film technology. This study showcases the feasibility, necessity and unlimited opportunities to transform laboratory nanoscience into nanotechnology through systems engineering of self-assembly.

42 ENGINEERING↗

DOE OSTI2020

Offset-aligned three-dimensional integrated circuit

A three-dimensional integrated circuit includes a first die having a first geometry. The first die includes a first region that operates with a first power density and a second region that operates with a second power density. The first power density is less than the second power density. The first die includes first electrical contacts disposed in the first region on a first side of the first die along a periphery of the first die. The three-dimensional integrated circuit includes a second die having a second geometry. The second die includes second electrical contacts disposed on a first side of the second die. A stacked portion of the second die is stacked within the periphery of the first die and an overhang portion of the second die extends beyond the periphery of the first die. The second electrical contacts are aligned with and coupled to the first electrical contacts.

42 ENGINEERING↗

DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗

DOE OSTI2022

A review of the fabrication methods and mechanical behavior of continuous thermoplastic polymer fiber–thermoplastic polymer matrix composites

Abstract Thermoplastic polymer fiber–thermoplastic polymer matrix composites (PPCs or PRFPs), often recognized as self‐reinforced or single polymer composites, are potential candidates for future advanced polymer composites because of various advantages ( e.g., recyclability, formability, low‐cost, ultra‐lightweight, environmental friendliness, etc.). The manufacturability and mechanical behavior of these composites compared to conventional carbon‐/glass‐/aramid‐fiber‐reinforced polymers is of great interest to the composites community, but there are a limited number of studies in this area. To this end, this paper reviewed fabrication methods with different processing parameters and mechanical behavior of uni‐/multi‐directional thermoplastic PPCs featuring continuous thermoplastic polymer fibers from limited data in the literature. It was shown that most specific behaviors (normalized by density) of these materials in various loading conditions (e.g., quasi‐static tension/shear/flexure, tension‐tension fatigue, and out‐of‐plane impacting, etc.) are comparable to or better than glass‐/aramid‐fiber‐reinforced polymers. Particularly, the specific ductility in the foregoing conditions outperforms all the carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Thermoplastic PPCs with remarkable performance can be achieved through several uncomplicated methods (e.g., film stacking, hot compaction, powder and solution impregnations, matrix infusion and injection molding, additive manufacturing, etc.), which have some similarities to the methods used for carbon‐/glass‐/aramid‐fiber‐reinforced polymers. Moreover, several opportunities and challenging problems of thermoplastic PPCs were summarized at the end of this review paper. Efficient solutions may require countless efforts in the composites community to further strengthen the performance and understanding of thermoplastic PPCs for wide applications in various engineering fields in the future.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Kinetic interplay between chemical short-range order and grain boundaries in NiCoCr alloys under irradiation

Chemical short-range order (CSRO) and grain boundary (GB) engineering are routes to enhance radiation damage tolerance in alloys. Here, we reveal that CSRO and GB interact in a sink-strength-dependent manner under irradiation in NiCoCr. Near a weak sink (Σ3 GB), CSRO reduces defect cluster growth by slowing interstitial diffusion and enhancing vacancy-interstitial recombinations. In contrast, near strong sinks such as Σ5 GBs, CSRO and GB act competitively for interstitial accumulation but synergistically to suppress large stacking-fault tetrahedra growth via enhanced recombination. Such mechanistic duality underscores the need for coordinated control of CSRO stability and GB sink strength to enhance radiation damage tolerance.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Hybrid Oscillator-Qubit Quantum Processors: Instruction Set Architectures, Abstract Machine Models, and Applications

This tutorial offers a pedagogical guide to hybrid quantum processors that integrate discrete-variable (DV) qubits and continuous-variable (CV) oscillators. Aimed at computer scientists, engineers, and physicists, it provides an overview of the experimental, algorithmic, and architectural aspects of this novel and rapidly developing hardware model. Experimental realizations of this model include superconducting, trapped-ion, and neutral-atom platforms. By combining DV and CV components, hybrid oscillator-qubit processors enable a powerful new paradigm that offers complementary strengths for quantum control, error correction, computation, and simulation. Working toward the goal of a full-stack system connecting applications to CV-DV hardware, we define and formulate abstract machine models and instruction set architectures. These essential abstractions enable codesign of hardware and software, and resource estimation for exploring the potential of current and future hardware for computational and simulation tasks. Using these abstractions, we present both new and existing examples that illustrate the benefits of hybrid CV-DV processors relative to traditional DV-only hardware in computation as well as quantum simulation of physical models. Examples include algorithms for transferring states between DV and CV systems, performing the quantum Fourier transform, and simulation of lattice gauge theories. Relative to qubit-only hardware, the bosonic degrees of freedom natively available in hybrid architectures can substantially reduce the circuit complexity of simulations for physical models containing bosons. A key technique is the extension of quantum signal processing ideas to CV-DV systems. This work is intended to serve as a timely and comprehensive guide to this relatively unexplored yet promising approach to quantum computation and to provide a road map to guide future development.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Stacked Low-Inertia Converter or Solid-State Transformer: Modeling and Model Predictive Priority-Shifting Control for Voltage Balance

This paper presents control challenges of stacked low-inertia converter (SLIC) or cascaded reduced dc-link solid-state transformer (SST) and proposes a novel model predictive priority-shifting (MPPS) control with implicit modulator and a discrete-time large-signal model for voltage balancing and dc-link regulation. Low-inertia converters, featuring small electrolytic capacitor-less dc links, dramatically reduce cost, size, and weight compared to conventional solutions. However, without a large dc-link buffer, the input and output are tightly coupled, leading to significant control challenges. The control becomes even more challenging with these converters stacked input-series output-parallel (ISOP) for medium-voltage (MV) grid, which causes coupling between the modules besides the coupling within each module. This paper analyzes the multi-objective, multi-degree of freedom control problem, using the modular soft-switching solid-state transformer (M-S4T) as an example of the SLIC. First, distribution of control efforts under controller saturation is critical because multiple control objectives can be conflicting, especially when the module voltages are unbalanced and are being restored. The MPPS can shift the priorities to address this issue. Second, due to the low inertia and high dc-link ripple, classic space vector pulse-width modulation (SVPWM), average model with small-ripple assumption, and control design based on small-signal model cannot accurately modulate, model, and control the nonlinear reduced dc link. Therefore, a discrete-time large-signal model of the M-S4T is established to derive the predictive control in the MPPS. The MPPS and the PI control are compared in MV simulations to show the issue of applying the PI to the SLIC and the effectiveness of the MPPS for voltage balancing and dc-link regulation in a deadbeat manner. Finally, the proposed control is tested on a 5 kV ISOP SiC SST prototype to verify priority shifting to address controller saturation issue and fast and robust voltage balancing.

14 SOLAR ENERGY↗

DOE OSTI2024

Qualification of Mixing Criteria by Computational Fluid Dynamics Modeling for the 325 Building Stack Revision

Additional ventilation capacity has been designed for the 325 Building filtered exhaust stack system. The four (4) existing main facility exhaust fans are past the end of their useful life. The fans are being replaced to provide additional exhaust capacity for future growth and to provide a more robust system. Stack operations will involve running various fan combinations at any given time. The air monitoring system of the existing stack previously was found to comply with the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard. Full-scale, three-dimensional computational fluid dynamics (CFD) modeling was used to evaluate the modified four-fan system for compliance with the ANSI/HPS N13.1-2021 standard, which essentially is equivalent in mixing requirements to the ANSI/HPS N13.1-1999 standard (and ANSI/HPS N13.1-2011). The four mixing criteria evaluated are 1) flow angle, 2) velocity, 3) gas tracer, and 4) particle tracer. In addition to the evaluating the modified four-fan system a temporary single fan stack configuration was also evaluated with CFD modeling. The temporary stack is planned to be used while the four-fan system is being modified. Modeling of the modified four-fan design and temporary ductwork showed that flow angles, velocity uniformity, gas tracer, and particle tracer were acceptable.

42 ENGINEERING↗

DOE OSTI2026

Trilinos: Enabling Scientific Computing across Diverse Hardware Architectures at Scale

Trilinos is a community-developed, open-source software framework that facilitates building large-scale, complex, multiscale, multiphysics simulation code bases for scientific and engineering problems. Since the Trilinos framework has undergone substantial changes to support new applications and new hardware architectures, this document is an update to “An Overview of the Trilinos project” by Heroux et al. (ACM Transactions on Mathematical Software, 31(3):397–423, 2005). It describes the design of Trilinos, introduces its new organization in product areas, and highlights established and new features available in Trilinos. Particular focus is put on the modernized software stack based on the Kokkos ecosystem to deliver performance portability across heterogeneous hardware architectures. This article also outlines the organization of the Trilinos community and the contribution model to help onboard interested users and contributors.

Heterogeneous Hardware Architectures↗

DOE OSTI2023

Higher order topological superconductivity in magnet-superconductor hybrid systems

Abstract Quantum engineering of topological superconductors and of the ensuing Majorana zero modes might hold the key for realizing topological quantum computing and topology-based devices. Magnet-superconductor hybrid (MSH) systems have proven to be experimentally versatile platforms for the creation of topological superconductivity by custom-designing the complex structure of their magnetic layer. Here, we demonstrate that higher order topological superconductivity (HOTSC) can be realized in two-dimensional MSH systems by using stacked magnetic structures. We show that the sensitivity of the HOTSC to the particular magnetic stacking opens an intriguing ability to tune the system between trivial and topological phases using atomic manipulation techniques. We propose that the realization of HOTSC in MSH systems, and in particular the existence of the characteristic Majorana corner modes, allows for the implementation of a measurement-based protocols for topological quantum computing.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

A New Era of Nuclear Criticality Experiments: The First 10 Years of Planet Operations at NCERC

Planet is a vertical-lift assembly machine currently located at the National Criticality Experiments Research Center (NCERC) at the Nevada National Security Site. In the past, Planet resided at Technical Area-18 in Los Alamos, New Mexico, as part of the Los Alamos Critical Experiments Facility (LACEF). Following the de-inventorying of LACEF, the Planet assembly was relocated to NCERC in 2008 and became fully operational in June of 2011. The Class Foils experiment, which involves stacking highly enriched uranium foils to obtain a critical configuration, was the first critical experiment performed on Planet. As a major component of the Nuclear Criticality Safety Class taught for the U.S. Department of Energy (DOE) Nuclear Criticality Safety Program, the Class Foils experiment allows personnel from all over the DOE complex to handle nuclear material and to complete the approach to critical safely and successfully. This paper describes the Planet vertical assembly and recent engineering upgrade and a selection of the experiments that have been performed on Planet since its transition to NCERC 10 years ago.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2010

Predicting Ares I Reaction Control System Performance by Utilizing Analysis Anchored with Development Test Data

The Ares I launch vehicle is an integral part of NASA s Constellation Program, providing a foundation for a new era of space access. The Ares I is designed to lift the Orion Crew Module and will enable humans to return to the Moon as well as explore Mars.1 The Ares I is comprised of two inline stages: a Space Shuttle-derived five-segment Solid Rocket Booster (SRB) First Stage (FS) and an Upper Stage (US) powered by a Saturn V-derived J-2X engine. A dedicated Roll Control System (RoCS) located on the connecting interstage provides roll control prior to FS separation. Induced yaw and pitch moments are handled by the SRB nozzle vectoring. The FS SRB operates for approximately two minutes after which the US separates from the vehicle and the US Reaction Control System (ReCS) continues to provide reaction control for the remainder of the mission. A representation of the Ares I launch vehicle in the stacked configuration and including the Orion Crew Exploration Vehicle (CEV) is shown in Figure 1. Each Reaction Control System (RCS) design incorporates a Gaseous Helium (GHe) pressurization system combined with a monopropellant Hydrazine (N2H4) propulsion system. Both systems have two diametrically opposed thruster modules. This architecture provides one failure tolerance for function and prevention of catastrophic hazards such as inadvertent thruster firing, bulk propellant leakage, and over-pressurization. The pressurization system on the RoCS includes two ambient pressure-referenced regulators on parallel strings in order to attain the required system level single Fault Tolerant (FT) design for function while the ReCS utilizes a blow-down approach. A single burst disk and relief valve assembly is also included on the RoCS to ensure single failure tolerance for must-not-occur catastrophic hazards. The Reaction Control Systems are designed to support simultaneously firing multiple thrusters as required

Stein, William B.↗

NASA NTRSDate not supplied

NASA’s Space Launch System: High C3 Launch Capability for Science Missions

As NASA’s initial Space Launch System (SLS) Block 1 vehicle enters integration and stacking operations at Kennedy Space Center (KSC) this year in preparation for a 2021 launch, work is in progress on future more powerful variants of the vehicle. Available in the mid 2020s and 2030s, Block 1B and Block 2 will feature increased performance and unparalleled volume for payloads, providing an enabling launch option for science mission planners. The baseline SLS architecture consists of two five-segment solid rocket boosters and four RS-25 LH2/LOX engines. The evolved Block 1B and Block 2 vehicles use a four-engine LH2/LOX upper stage and can be outfitted with an 8.4 m-diameter pay-load fairing. Additional upper stages can be packaged in the 8.4 m fairing to enable high C3 (in the range of 300 km2/sec2) missions to Mercury, the Jovian system, the ice giants, the Kuiper Belt and beyond.

Stephen D Creech↗

DOE OSTI2024

How to Build a Quantum Supercomputer: Scaling from Hundreds to Millions of Qubits

In the span of four decades, quantum computation has evolved from an intellectual curiosity to a potentially realizable technology. Today, small-scale demonstrations have become possible for quantum algorithmic primitives on hundreds of physical qubits and proof-of-principle error-correction on a single logical qubit. Nevertheless, despite significant progress and excitement, the path toward a full-stack scalable technology is largely unknown. There are significant outstanding quantum hardware, fabrication, software architecture, and algorithmic challenges that are either unresolved or overlooked. These issues could seriously undermine the arrival of utility-scale quantum computers for the foreseeable future. Here, we provide a comprehensive review of these scaling challenges. We show how the road to scaling could be paved by adopting existing semiconductor technology to build much higher-quality qubits, employing system engineering approaches, and performing distributed quantum computation within heterogeneous high-performance computing infrastructures. These opportunities for research and development could unlock certain promising applications, in particular, efficient quantum simulation/learning of quantum data generated by natural or engineered quantum systems. To estimate the true cost of such promises, we provide a detailed resource and sensitivity analysis for classically hard quantum chemistry calculations on surface-code error-corrected quantum computers given current, target, and desired hardware specifications based on superconducting qubits, accounting for a realistic distribution of errors. Furthermore, we argue that, to tackle industry-scale classical optimization and machine learning problems in a cost-effective manner, heterogeneous quantum-probabilistic computing with custom-designed accelerators should be considered as a complementary path toward scalability.

Mohseni, Masoud↗

DOE OSTI2025

Enhancing Thermal Transport in Polymeric Composites Via Engineered Noncovalent Filler–Polymer Interactions

Understanding thermal transport mechanisms in polymeric composites allows us to expand the boundaries of thermal conductivity in them, either increasing it for more efficient heat dissipation or decreasing it for better thermal insulation. But, these mechanisms are not fully understood. Systematic experimental investigations remain limited. Practical strategies to tune the interfacial thermal resistance (ITR) between fillers and polymers and the thermal conductivity of composites remain elusive. Here, we studied the thermal transport in representative polymer composites, using polyethylene (PE) or polyaniline (PANI) as matrices and graphite as fillers. PANI, with aromatic rings in its backbone, interacts with graphite through strong noncovalent π–π stacking interactions, whereas PE lacks such interactions. We can then quantify how π–π stacking interactions between graphite and polymers enhance thermal transport in composites. PE/graphite and PANI/graphite composites with the same 1.5% filler volume fractions show a ∼22.82% and ∼34.85% enhancement in thermal conductivity compared to pure polymers, respectively. Calculated ITRs in PE/graphite and PANI/graphite are ~6 x 10 -8 m 2 KW -1 and ~1 x 10 -8 m 2 KW -1 , respectively, highlighting how π–π stacking interactions reduce ITR. Molecular dynamics (MD) simulations suggest that π–π stacking interactions between PANI chains and graphite surfaces enhance alignment of PANI's aromatic rings with graphite surfaces. This allows more carbon atoms from PANI chains to interact with graphite surfaces at a shorter distance compared to PE chains. Finally, our work indicates that tuning the π–π stacking interactions between polymers and fillers is an effective approach to reduce the ITR and enhance the thermal conductivity of composites.

atoms↗

DOE OSTI2024

Picosecond Ultrasonics in Magnetic Topological Insulator MnBi 2 Te 4

MnBi 2 Te 4 is a magnetic topological insulator with layered A-type antiferromagnetic order. It exhibits a rich layer- and magnetic-state dependent topological phase diagram; however, much about the coupling between spin, charge, and lattice remains to be explored. Here, in this work, we report that MnBi 2 Te 4 is an excellent acoustic phonon cavity by realizing phonon frequency combs using picosecond ultrasonics. With the generated acoustic phonon wavepackets, we demonstrate that the timing and phase of acoustic echoes can be used to detect the presence of stacking faults between van der Waals layers buried deep within the crystal. Furthermore, by implementing this nondestructive ultrafast optical measurement in conjunction with time-resolved magneto-optical Kerr effect experiments, we uncover that out-of-plane vibrations in MnBi 2 Te 4 do not couple to the magnetic order, i.e. there is no appreciable magnetostriction. Our work points out how a well-developed technique can probe the structural defects and phonon pulse engineering in layered topological insulators.

36 MATERIALS SCIENCE↗

DOE OSTI2026

HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION

The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

Wasti, Sanjita [ORNL]↗