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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Lift Optimization Study of a Multi-Element Three-Segment Variable Camber Airfoil

This paper reports a detailed computational high-lift study of the Variable Camber Continuous Trailing Edge Flap (VCCTEF) system carried out to explore the best VCCTEF designs, in conjunction with a leading edge flap called the Variable Camber Krueger (VCK), for take-off and landing. For this purpose, a three-segment variable camber airfoil employed as a performance adaptive aeroelastic wing shaping control effector for a NASA Generic Transport Model (GTM) in landing and take-off configurations is considered. The objective of the study is to define optimal high-lift VCCTEF settings and VCK settings/configurations. A total of 224 combinations of VCK settings/configurations and VCCTEF settings are considered for the inboard GTM wing, where the VCCTEFs are configured as a Fowler flap that forms a slot between the VCCTEF and the main wing. For the VCK settings of deflection angles of 55deg, 60deg and 65deg, 18, 19 and 19 vck configurations, respectively, were considered for each of the 4 different VCCTEF deflection settings. Different vck configurations were defined by varying the horizontal and vertical distance of the vck from the main wing. A computational investigation using a Reynolds-Averaged Navier-Stokes (RANS) solver was carried out to complement a wind-tunnel experimental study covering three of these configurations with the goal of identifying the most optimal high-lift configurations. Four most optimal high-lift configurations, corresponding to each of the VCK deflection settings, have been identified out of all the different configurations considered in this study yielding the highest lift performance.

Study↗
DOE OSTI2026

Online task-space motion control for positioner-coordinated multi-robot manufacturing systems

Incorporating multiple robotic manipulators into large-scale manufacturing systems enhances production efficiency and expands manufacturing capabilities beyond those of single-robot systems. Workpiece positioners in robotic manufacturing have demonstrated significant benefits for process optimization, but coordination strategies for multi-robot systems with shared positioners have received limited attention. This work presents a task-space coordinated trajectory-tracking control framework for multi-robot manufacturing systems, in which robots coordinate their motions within a shared, dynamic workpiece positioning frame. A workpiece positioner actively adjusts the pose of the manufactured component to enable greater operational concurrency and improve overall production efficiency. The proposed motion-coordination scheme employs a distributed and scalable architecture, supporting coordination across heterogeneous multi-robot systems. Two optimization methodologies are introduced to manage kinematic redundancies and maintain continuous, near-optimal operation throughout the manufacturing process. The first strategy exploits a task-space dimensionality reduction to achieve locally optimal configurations by leveraging symmetry-axis rotations of the tool. The second strategy utilizes the workpiece positioner to drive the coordinated robots toward stable and kinematically favorable configurations. For both optimization strategies, multiple objectives are defined to improve key performance metrics, including manipulability, configuration consistency, proximity to mechanical limits, and motion efficiency. Addressing a key limitation of existing coordination approaches, the framework is designed around online setpoint modification, allowing coordinated robots to respond effectively to in-situ process feedback. The proposed control framework is validated using the Robot Operating System (ROS) middleware on a combination of physical and simulated multi-robot system hardware.

Arbogast, Alex [ORNL] (ORCID:0000000154740723)↗
NASA NTRS2006

Studying Galaxy Formation with the Hubble, Spitzer and James Webb Space Telescopes

The deepest optical to infrared observations of the universe include the Hubble Deep Fields, the Great Observatories Origins Deep Survey and the recent Hubble Ultra-Deep Field. Galaxies are seen in these surveys at redshifts 2-6, less than 1 Gyr after the Big Bang, at the end of a period when light from the galaxies has reionized Hydrogen in the inter-galactic medium. These observations, combined with theoretical understanding, indicate that the first stars and galaxies formed at z>10, beyond the reach of the Hubble and Spitzer Space Telescopes. To observe the first galaxies, NASA is planning the James Webb Space Telescope (JWST), a large (6.5m), cold (50K), infrared-optimized observatory to be launched early in the next decade into orbit around the second Earth- Sun Lagrange point. JWST will have four instruments: The Near-Infrared Camera, the Near-Infrared multi-object Spectrograph, and the Tunable Filter Imager will cover the wavelength range 0.6 to 5 microns, while the Mid-Infrared Instrument will do both imaging and spectroscopy from 5 to 27 microns. In addition to JWST s ability to study the formation and evolution of galaxies, I will also briefly review its expected contributions to studies of the formation of stars and planetary systems.

Gardner, Jonathan F.↗
NASA NTRS2007

Studying Galaxy Formation with the Hubble, Spitzer and James Webb Space Telescopes

The deepest optical to infrared observations of the universe include the Hubble Deep Fields, the Great Observatories Origins Deep Survey and the recent Hubble Ultra-Deep Field. Galaxies are seen in these surveys at redshifts 2x3, less than 1 Gyr after the Big Bang, at the end of a period when light from the galaxies has reionized Hydrogen in the inter-galactic medium. These observations, combined with theoretical understanding, indicate that the first stars and galaxies formed at z>lO, beyond the reach of the Hubble and Spitzer Space Telescopes. To observe the first galaxies, NASA is planning the James Webb Space Telescope (JWST), a large (6.5m), cold (<50K), infrared-optimized observatory to be launched early in the next decade into orbit around the second Earth- Sun Lagrange point. JWST will have four instruments: The Near-Infrared Camera, the Near-Infrared multi-object Spectrograph, and the Tunable Filter Imager will cover the wavelength range 0.6 to 5 microns, while the Mid-Infrared Instrument will do both imaging and spectroscopy from 5 to 28.5 microns. In addition to JWST's ability to study the formation and evolution of galaxies, I will also briefly review its expected contributions to studies of the formation of stars and planetary systems.

Gardner, Jonathan P.↗
NASA NTRS2008

Studying Galaxy Formation and Reionization with the James Webb Space Telescope

The deepest optical to infrared observations of the universe include the Hubble Deep Fields, the Great Observatories Origins Deep Survey and the recent Hubble Ultra-Deep Field. Galaxies are seen in these surveys at redshifts z>6, less than 1 Gyr after the Big Bang, at the end of a period when light from the galaxies has reionized Hydrogen in the inter-galactic medium. These observations, combined with theoretical understanding, indicate that the first stars and galaxies formed at z>10, beyond the reach of the Hubble and Spitzer Space Telescopes. To observe the first galaxies, NASA is planning the James Webb Space Telescope (JWST), a large (6.5m), cold (<50K), infrared-optimized observatory to be launched early in the next decade into orbit around the second Earth- Sun Lagrange point. JWST will have four instruments: The Near-Infrared Camera, the Near-Infrared multi-object Spectrograph, and the Tunable Filter Imager will cover the wavelength range 0.6 to 5 microns, while the Mid-Infrared Instrument will do both imaging and spectroscopy from 5 to 28.5 microns. I will review the current status of the project.

Gardner, Jonathan P.↗
NASA NTRS2007

Studying Galaxy Formation with the Hubble, Spitzer and James Webb Space Telescopes

The deepest optical to infrared observations of the universe include the Hubble Deep Fields, the Great Observatories Origins Deep Survey and the recent Hubble Ultra-Deep Field. Galaxies are seen in these surveys at redshifts z>6, less than 1 Gyr after the Big Bang, at the end of a period when light from the galaxies has reionized Hydrogen in the inter-galactic medium. These observations, combined with theoretical understanding, indicate that the first stars and galaxies formed at z>10, beyond the reach of the Hubble and Spitzer Space Telescopes. To observe the first galaxies, NASA is planning the James Webb Space Telescope (JWST), a large (6.5m), cold (<50K), infrared-optimized observatory to be launched early in the next decade into orbit around the second Earth- Sun Lagrange point. JWST will have four instruments: The Near-Infrared Camera, the Near-Infrared multi-object Spectrograph, and the Tunable Filter Imager will cover the wavelength range 0.6 to 5 microns, while the Mid-Infrared Instrument will do both imaging and spectroscopy from 5 to 28.5 microns. In addition to JWST's ability to study the formation and evolution of galaxies, I will also briefly review its expected contributions to studies of the formation of stars and planetary systems.

Gardner, Jonathan P.↗
DOE OSTI2026

Crystal generation using the fully differentiable pipeline and latent space optimization

We present a materials generation framework that couples a symmetry-conditioned variational autoencoder with a differentiable SO(3) power spectrum objective to steer candidates toward a specified local environment under the crystallographic constraints. In particular, we implement a fully differentiable pipeline that performs batch-wise optimization on both direct and latent crystallographic representations. Using the GPU acceleration, the implementation achieves about fivefold speed compared to our previous CPU workflow, while yielding comparable outcomes. In addition, we introduce the optimization strategy that alternatively performs optimization on the direct and latent crystal representations. This dual-level relaxation approach can effectively escape local minima defined by different objective gradients, thus increasing the success rate of generating complex structures satisfying the target local environments. This framework can be extended to systems consisting of multi-components and multi-environments, providing a scalable route to generate material structures with the target local environment.

conditional VAE↗
NASA NTRS2012

Studies of Supernovae, SNR, and Dust with the James Webb Space Telescope

The james Webb Space Telescope (JWST) will provide breakthrough capabilities for the study of supernovae and supernova remnants, as well as many other science objectives. JWST is a large aperture, cryogenic, infrared-optimized general purpose space observatory under construction by NASA, ESA, and CSA for launch in 2018. The JWST instrumentation will provide imaging, coronagraphy, and spectroscopy between 6000A to 29 microns. This spectral region contains many atomic, molecular, and particulate diagnostics that are especially relevant for the study of dust formation. The spectroscopic capabilities include velocity resolution down to approx. 100 km/sec, a near-IR multi-object spectrograph with a approx. 3x3 arcmin field of view array of approx. 250,000 addressable shutters, and near-IR and mid-IR approx. 3x3 arcsec integral field units. The JWST telescope will have a 6.5m-diameter segmented primary mirror and will be diffraction-limited at 2 microns (PSF FWHM - 0.07 arcsec). The imaging and spectroscopic sensitivities will be about 100x lower than previous capabilities in the near- and mid-IR. The JWST observatory will be placed in a L2 orbit by an Ariane 5 launch vehicle provided by ESA. The JWST telescope and instruments will be passively cooled to approx. 40K by a sunshield that will be unfolded after launch. The sunshield geometry limits the JWST pointing on the sky to be between 85 deg and 135 deg from the Sun. The observatory is designed for a 5-year prime science mission, with consumables for 10 years of science operations, and a Target of Opportunity response time of 48 hours.

Sonneborn, George↗
NASA NTRS2009

Studying Galaxy Formation with the Hubble, Spitzer and James Webb Space Telescopes

The deepest optical to infrared observations of the universe include the Hubble Deep Fields, the Great Observatories Origins Deep Survey and the recent Hubble Ultra-Deep Field. Galaxies are seen in these surveys at redshifts z greater than 6, less than 1 Gyr after the Big Bang, at the end of a period when light from the galaxies has reionized Hydrogen in the inter-galactic medium. These observations, combined with theoretical understanding, indicate that the first stars and galaxies formed at z greater than 10, beyond the reach of the Hubble and Spitzer Space Telescopes. To observe the first galaxies, NASA is planning the James Webb Space Telescope (JWST), a large (6.5m), cold (less than 50K), infrared-optimized observatory to be launched early in the next decade into orbit around the second Earth-Sun Lagrange point. JWST will have four instruments: The Near-Infrared Camera, the Near-Infrared multi-object Spectrograph, and the Tunable Filter Imager will cover the wavelength range 0.6 to 5 microns, while the Mid-Infrared Instrument will do both imaging and spectroscopy from 5 to 28.5 microns. In addition to JWST's ability to study the formation and evolution of galaxies, I will also briefly review its expected contributions to studies of the formation of stars and planetary systems, and discuss recent progress in constructing the observatory.

Gardner, Jonathan P.↗
DOE OSTI2021

Multi-objective parametrization of interatomic potentials for large deformation pathways and fracture of two-dimensional materials

Abstract This investigation presents a generally applicable framework for parameterizing interatomic potentials to accurately capture large deformation pathways. It incorporates a multi-objective genetic algorithm, training and screening property sets, and correlation and principal component analyses. The framework enables iterative definition of properties in the training and screening sets, guided by correlation relationships between properties, aiming to achieve optimal parametrizations for properties of interest. Specifically, the performance of increasingly complex potentials, Buckingham, Stillinger-Weber, Tersoff, and modified reactive empirical bond-order potentials are compared. Using MoSe 2 as a case study, we demonstrate good reproducibility of training/screening properties and superior transferability. For MoSe 2 , the best performance is achieved using the Tersoff potential, which is ascribed to its apparent higher flexibility embedded in its functional form. These results should facilitate the selection and parametrization of interatomic potentials for exploring mechanical and phononic properties of a large library of two-dimensional and bulk materials.

Zhang, Xu↗
NASA NTRS2003

Evaluation of Genetic Algorithm Concepts using Model Problems: Single-Objective Optimization - Part 1

A genetic-algorithm-based optimization approach is described and evaluated using a simple hill-climbing model problem. The model problem utilized herein allows for the broad specification of a large number of search spaces including spaces with an arbitrary number of genes or decision variables and an arbitrary number hills or modes. In the present study, only single objective problems are considered. Results indicate that the genetic algorithm optimization approach is flexible in application and extremely reliable, providing optimal results for all problems attempted. The most difficult problems - those with large hyper-volumes and multi-mode search spaces containing a large number of genes - require a large number of function evaluations for GA convergence, but they always converge.

Holst, Terry L.↗
NASA NTRS1990

A homotopy approach for combined control-structure optimization - Constructive analysis and numerical examples

This paper outlines the development of methods for the combined control-structure optimization of physical systems encountered in the technology of large space structures. The objectives of the approach taken in this paper is not to produce the 'best' optimized design, but rather to efficiently produce a family of design options so as to assist in early trade studies, typically before hard design constraints are imposed. The philosophy is that these are candidate designs to be passed on for further considerations, and their function is more to guide the development of the system design rather than to represent the ultimate product. A homotopy approach involving multi-objective functions is developed for this purpose. Analytical and numerical examples are also presented.

Scheid, R. E.↗
NASA NTRS1989

Methods for combined control-structure optimization

This paper outlines the development of methods for the combined control-structure optimization of physical systems encountered in the technology of large space structures. The objective of the approach taken in this paper is not to produce the 'best' optimized design, but rather to efficiently produce a family of design options so as to asist in early trade studies, typically before hard design constraints are imposed. The philosophy is that these are candidate designs to be passed on for further consideration, and their function is more to guide the development of the system design rather than to represent the ultimate product. A homotopy approach involving multi-objective functions is developed for this purpose, and a numerical example is presented.

Milman, M.↗
DOE OSTI2021

Computational catalyst discovery: Active classification through myopic multiscale sampling

We report the recent boom in computational chemistry has enabled several projects aimed at discovering useful materials or catalysts. We acknowledge and address two recurring issues in the field of computational catalyst discovery. First, calculating macro-scale catalyst properties is not straightforward when using ensembles of atomic-scale calculations [e.g., density functional theory (DFT)]. We attempt to address this issue by creating a multi-scale model that estimates bulk catalyst activity using adsorption energy predictions from both DFT and machine learning models. The second issue is that many catalyst discovery efforts seek to optimize catalyst properties, but optimization is an inherently exploitative objective that is in tension with the explorative nature of early-stage discovery projects. In other words, why invest so much time finding a “best” catalyst when it is likely to fail for some other, unforeseen problem? We address this issue by relaxing the catalyst discovery goal into a classification problem: “What is the set of catalysts that is worth testing experimentally?” Here, we present a catalyst discovery method called myopic multiscale sampling, which combines multiscale modeling with automated selection of DFT calculations. It is an active classification strategy that seeks to classify catalysts as “worth investigating” or “not worth investigating” experimentally. Our results show an ~7–16 times speedup in catalyst classification relative to random sampling. These results were based on offline simulations of our algorithm on two different datasets: a larger, synthesized dataset and a smaller, real dataset.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Fuzzified PaCcET for Economic-Emission Scheduling of Microgrids

In this paper, a new approach is proposed to solve a multi-objective economic-emission scheduling problem in microgrids (MGs) by simultaneously minimizing the energy and emission costs of the MG with various distributed energy resources (DERs). The proposed approach is an extension of a computationally effective multiobjective optimization technique, Pareto concavity elimination transformation (PaCcET). The proposed approach, referred to as Fuzzified-PaCcET, employs a fuzzy logic controller to dynamically revise crossover and mutation rates in the original PaCcET leading to the faster convergence of the solution. The proposed approach finds the best Pareto front, also referred to as a Non-dominated set (NDS) of solutions, instead of finding a single optimal solution. In order to find the solutions on concave areas of the Pareto front, an iterative objective space transformation is performed in the PaCcET algorithm to allow a linear combination of objective functions (in the transformed objective space). The proposed Fuzzified-PaCcET-based scheduling is implemented on a MG with various dispatchable and non-dispatchable DERs to find the set of optimal solutions according to the total fuel cost of DERs, as well as the most optimum environmental cost. In order to extract the best compromise solution (BCS) among NDS of solutions, a fuzzy-based method is implemented. The comparison of the simulation results of the Fuzzified-PaCcET with that of PaCcET shows that Fuzzified-PaCcET can generate better solution with less computational burden.

Gautam, Mukesh↗