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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Runtime Assurance Protection for Advanced Turbofan Engine Control

This paper describes technical progress made in the application of run time assurance (RTA) methods to turbofan engines with advanced propulsion control algorithms that are employed to improve engine performance. It is assumed that the advanced algorithms cannot be fully certified using current verification and validation approaches and therefore need to be continually monitored by an RTA system that ensures safe operation. However, current turbofan engine control systems utilize engine protection logic for safe combustion dynamics and stable airflow through the engine. It was determined that the engine protection logic should continue to be used to provide system safety and should be considered as a part of the overall RTA system. The additional function that an RTA system provides is to perform diagnostics on anomalous conditions to determine if these conditions are being caused by errors in the advanced controller. If this is the case, the RTA system switches operation to a trusted reversionary controller. Initial studies were performed to demonstrate this benefit. The other focus was to improve the performance of the engine protection logic, which was deemed too conservative and reduced engine performance during transient operations. It was determined that the conservative response was due to poor tuning of one of the controller channels within the protection logic. An automatic tuning algorithm was implemented to optimize the protection logic control gains based on minimizing tracking error. Improved tracking responses were observed with no change to the existing protection logic control architecture.

runtime monitoring↗
DOE OSTI2021

Manifold Sampling for Optimizing Nonsmooth Nonconvex Compositions

Here we propose a manifold sampling algorithm for minimizing a nonsmooth composition $f= h\circ F$, where we assume $h$ is nonsmooth and may be inexpensively computed in closed form and $F$ is smooth but its Jacobian may not be available. We additionally assume that the composition $h\circ F$ defines a continuous selection. Manifold sampling algorithms can be classified as model-based derivative-free methods, in that models of $F$ are combined with particularly sampled information about $h$ to yield local models for use within a trust-region framework. We demonstrate that cluster points of the sequence of iterates generated by the manifold sampling algorithm are Clarke stationary. We consider the tractability of three particular subproblems generated by the manifold sampling algorithm and the extent to which inexact solutions to these subproblems may be tolerated. Numerical results demonstrate that manifold sampling as a derivative-free algorithm is competitive with state-of-the-art algorithms for nonsmooth optimization that utilize first-order information about $f$.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2006

Verification of Autonomous Systems for Space Applications

Autonomous software, especially if it is based on model, can play an important role in future space applications. For example, it can help streamline ground operations, or, assist in autonomous rendezvous and docking operations, or even, help recover from problems (e.g., planners can be used to explore the space of recovery actions for a power subsystem and implement a solution without (or with minimal) human intervention). In general, the exploration capabilities of model-based systems give them great flexibility. Unfortunately, it also makes them unpredictable to our human eyes, both in terms of their execution and their verification. The traditional verification techniques are inadequate for these systems since they are mostly based on testing, which implies a very limited exploration of their behavioral space. In our work, we explore how advanced V&V techniques, such as static analysis, model checking, and compositional verification, can be used to gain trust in model-based systems. We also describe how synthesis can be used in the context of system reconfiguration and in the context of verification.

Brat, G.↗
NASA NTRS1975

ATS-6 - Television Relay Using Small Terminals Experiment

The Television Relay Using Small Terminals (TRUST) Experiment was designed to advance and promote the technology of broadcasting satellites. A constant envelope television FM signal was transmitted at C band to the ATS-6 earth coverage horn and retransmitted at 860 MHz through the 9-m antenna to a low-cost direct-readout ground station. The experiment demonstrated that high-quality television and audio can be received by low-cost direct-receive ground stations. Predetection bandwidths significantly less than predicted by Carson's rule can be utilized with minimal degradation of either monochrome or color pictures. Two separate techniques of dual audio channel transmission have been demonstrated to be suitable for low-cost applications.

Miller, J. E.↗
DOE OSTI2021

Randomized Sketching Algorithms for Low-Memory Dynamic Optimization

This paper develops a novel limited-memory method to solve dynamic optimization problems. The memory requirements for such problems often present a major obstacle, particularly for problems with PDE constraints such as optimal flow control, full waveform inversion, and optical tomography. In these problems, PDE constraints uniquely determine the state of a physical system for a given control; the goal is to find the value of the control that minimizes an objective. While the control is often low dimensional, the state is typically more expensive to store. This paper suggests using randomized matrix approximation to compress the state as it is generated and shows how to use the compressed state to reliably solve the original dynamic optimization problem. Concretely, the compressed state is used to compute approximate gradients and to apply the Hessian to vectors. The approximation error in these quantities is controlled by the target rank of the sketch. This approximate first- and second-order information can readily be used in any optimization algorithm. As an example, we develop a sketched trust-region method that adaptively chooses the target rank using a posteriori error information and provably converges to a stationary point of the original problem. Numerical experiments with the sketched trust-region method show promising performance on challenging problems such as the optimal control of an advection-reaction-diffusion equation and the optimal control of fluid flow past a cylinder.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2011

The Analysis of Rush Orders Risk in Supply Chain: A Simulation Approach

Satisfying customers by delivering demands at agreed time, with competitive prices, and in satisfactory quality level are crucial requirements for supply chain survival. Incidence of risks in supply chain often causes sudden disruptions in the processes and consequently leads to customers losing their trust in a company's competence. Rush orders are considered to be one of the main types of supply chain risks due to their negative impact on the overall performance, Using integrated definition modeling approaches (i.e. IDEF0 & IDEF3) and simulation modeling technique, a comprehensive integrated model has been developed to assess rush order risks and examine two risk mitigation strategies. Detailed functions sequence and objects flow were conceptually modeled to reflect on macro and micro levels of the studied supply chain. Discrete event simulation models were then developed to assess and investigate the mitigation strategies of rush order risks, the objective of this is to minimize order cycle time and cost.

Mahfouz, Amr↗
NASA NTRSDate not supplied

A Distributed Simulation-to-Flight Framework to Support Investigating Trust/Trustworthiness in Multi-Agent Systems

As autonomous systems continue to grow both in use and complexity, the necessity for robust and extensible simulation-to-flight frameworks is paramount for establishing an effective architecture for autonomous systems. Hardware test flights are time-consuming and cost prohibitive during early system design and development. Simulation environments can be useful tools to accelerate algorithm development and testing. However, transitions from simulation to flight (sim-to-flight) can be challenging, unless systems are designed with this transition in mind and with the necessary capabilities built into the architecture and framework. One of the objectives of Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) was to design and develop a distributed mixed-reality simulation environment to begin establishing a basis for certification of autonomous systems via research into trust and trustworthiness. ATTRACTOR’s objective was to construct computational concepts of trustworthiness and justifiable trust in multi-agent autonomous teams, to inform future certification of safety-critical and time-critical autonomous systems in aviation. In this paper, we present an autonomous systems architecture and development framework paired with a persistent distributed modeling and simulation (ModSim) environment for test and evaluation of autonomous systems. They were designed under ATTRACTOR in order to measure and establish trustworthiness and trust in single-and multi-agent human-machine systems whether these machines are fixed-wing general aviation, rotary-wing Unmanned Aerial Vehicles (UAVs), ground rovers, or even spacecraft. The Autonomous Entity Operational Network (AEON) framework enables autonomous system development with an easily extensible collection of libraries and plug-n-play nodes facilitated by the Data Distribution Service (DDS) communication protocol standard. The Baseline Environment for Autonomous Modeling (BEAM) simulation environment is a distributed mixed-reality Unity™-based environment built around the same DDS communication paradigm allowing for easy integration with AEON-based autonomous applications, enabling sim-to-flight with minimal configuration changes. Using AEON and BEAM, source code that runs in simulation ports directly to hardware and has successfully flown in the National Airspace System (NAS) at NASA LaRC many times over the lifetime of ATTRACTOR.

Benjamin N Kelley↗
DOE OSTI2021

A Minimal Information Set To Enable Verifiable Theoretical Battery Research

Batteries are an enabling technology for addressing sustainability through the electrification of various forms of transportation (1) and grid storage. (2) Batteries are truly multi-scale, multi-physics devices, and accordingly various theoretical descriptions exist to understand their behavior (3-5) ranging from atomistic details to techno-economic trends. As we explore advanced battery chemistries (6,7) or previously inaccessible aspects of existing ones, (8-10) new theories are required to drive decisions. (11-13) The decisions are influenced by the limitations of the underlying theory. Advanced theories used to understand battery phenomena are complicated and require substantial effort to reproduce. However, such constraints should not limit the insights from these theories. We can strive to make the theoretical research verifiable such that any battery stakeholder can assess the veracity of new theories, sophisticated simulations or elaborate analyses. We distinguish verifiability, which amounts to “Can I trust the results, conclusions and insights and identify the context where they are relevant?”, from reproducibility, which ensures “Would I get the same results if I followed the same steps?” With this motivation, we propose a checklist to guide future reports of theoretical battery research in Table 1. We hereafter discuss our thoughts leading to this and how it helps to consistently document necessary details while allowing complete freedom for creativity of individual researchers. Given the differences between experimental and theoretical studies, the proposed checklist differs from its experimental counterparts. (14,15) This checklist covers all flavors of theoretical battery research, ranging from atomic/molecular calculations (16-19) to mesoscale (20,21) and continuum-scale interactions, (9,22) and techno-economic analysis. (23,24) Finally, as more and more experimental studies analyze raw data, (25) we feel this checklist would be broadly relevant.

25 ENERGY STORAGE↗
DOE OSTI2023

The DESC stellarator code suite Part 3: Quasi-symmetry optimization

The DESC stellarator optimization code takes advantage of advanced numerical methods to search the full parameter space much faster than conventional tools. Only a single equilibrium solution is needed at each optimization step thanks to automatic differentiation, which efficiently provides exact derivative information. A Gauss–Newton trust-region optimization method uses second-order derivative information to take large steps in parameter space and converges rapidly. With just-in-time compilation and GPU portability, high-dimensional stellarator optimization runs take orders of magnitude less computation time with DESC compared to other approaches. This paper presents the theory of the DESC fixed-boundary local optimization algorithm along with demonstrations of how to easily implement it in the code. Example quasi-symmetry optimizations are shown and compared to results from conventional tools. Three different forms of quasi-symmetry objectives are available in DESC, and their relative advantages are discussed in detail. In the examples presented, the triple product formulation yields the best optimization results in terms of minimized computation time and particle transport. This paper concludes with an explanation of how the modular code suite can be extended to accommodate other types of optimization problems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Binary Control Pulse Optimization for Quantum Systems

Quantum control aims to manipulate quantum systems toward specific quantum states or desired operations. Designing highly accurate and effective control steps is vitally important to various quantum applications, including energy minimization and circuit compilation. In this paper we focus on discrete binary quantum control problems and apply different optimization algorithms and techniques to improve computational efficiency and solution quality. Specifically, we develop a generic model and extend it in several ways. We introduce a squared L 2 -penalty function to handle additional side constraints, to model requirements such as allowing at most one control to be active. We introduce a total variation (TV) regularizer to reduce the number of switches in the control. We modify the popular gradient ascent pulse engineering (GRAPE) algorithm, develop a new alternating direction method of multipliers (ADMM) algorithm to solve the continuous relaxation of the penalized model, and then apply rounding techniques to obtain binary control solutions. We propose a modified trust-region method to further improve the solutions. Our algorithms can obtain high-quality control results, as demonstrated by numerical studies on diverse quantum control examples.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Optimal Client Sampling in Federated Learning with Client-level Heterogeneous Differential Privacy

Federated Learning with client-level differential privacy (DP) provides a promising framework for collaboratively training models while rigorously protecting clients’ privacy. However, classic approaches like DP-FedAvg struggle when clients have heterogeneous privacy requirements, as they must uniformly enforce the strictest privacy level across all clients, leading to excessive DP noise and significant degradation in model utility. Existing methods to improve the model utility in such heterogeneous privacy settings often assume a trusted server and are largely heuristic, resulting in suboptimal performance and lacking strong theoretical foundations. Here, in this work, we address these challenges under a practical attack model where both clients and the server are honest-but-curious. We propose GDPFed, which partitions clients into groups based on their privacy budgets and achieves client-level DP within each group to reduce the privacy budget waste and hence improve the model utility. Based on the privacy and convergence analysis of GDPFed, we find that the magnitude of DP noise depends on both model dimensionality and the per-group client sampling ratios. To further improve the performance of GDPFed, we introduce GDPFed+, which integrates model sparsification to eliminate unnecessary noise and optimizes per-group client sampling ratios to minimize convergence error. Extensive empirical evaluations on multiple benchmark datasets demonstrate the effectiveness of GDPFed+, showing substantial performance gains compared with state-of-the-art methods.

Xu, Jiahao [Univ. of Nevada, Reno, NV (United Stat↗
DOE OSTI2025

Technical Assessment of the Application of Digital Twin and Prognostic Tools for Condition Monitoring

This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to present use cases of the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components (SSCs). The advanced technologies considered in this work, collectively referred to as digital twin (DT) technologies, are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), and physics-based models. The report presents two use cases of reactor coolant pumps (RCPs) and heat pipes in nuclear power plants (NPPs) with technical and regulatory considerations and opportunities in using advanced technologies for conditional monitoring. Key findings from the exploration of these considerations are as follows: - Uncertainties in sensor data and model predictions must be rigorously addressed through validation and verification processes - Regulatory compliance is paramount, necessitating data driven models to be developed in line with existing codes and standards, as well as considering potential future guidelines for advanced reactors - Explainability and transparency in ML/AI models are essential for developing operator trust and regulatory review, including methods that enhance the interpretability of complex data-driven predictions - Condition monitoring programs must be evaluated for their effectiveness in reducing maintenance-preventable function failures (MPFF) and aligning with plant performance criteria - The deployment of advanced technologies for condition monitoring could lead to a transition from periodic to continuous monitoring, thereby optimizing maintenance schedules - Collaborative efforts between industry stakeholders, regulatory bodies, and technology developers are crucial for the successful adoption of advanced technologies for condition monitoring systems in nuclear facilities In summary, the introduction of advanced technologies into condition monitoring programs represents a significant leap forward in the domain of NPP maintenance. By harnessing the capabilities of advanced sensors, data analytics, and ML/AI, NPP operators can transition from a time-based to a condition-based maintenance approach. This shift can potentially enhance the reliability and safety of critical plant components while optimizing maintenance efforts and minimizing unnecessary outages. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of inservice inspection and inservice testing (ISI and IST) programs by pursuing additional research in this technical area.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Advanced Transmission Technologies – GETs and HPCs Session 2: Advanced Power Flow Control and Transmission Topology Optimization

The INL TADA GETs Cohort Session 2, held on November 7, 2025, conducted in collaboration with ScottMadden, focused on two core Advanced Transmission Technologies (ATTs): Advanced Power Flow Control (APFC) and Transmission Topology Optimization (TTO). These technologies are pivotal in enhancing grid flexibility, reliability, and cybersecurity resilience. APFC, particularly through modular FACTS devices like Modular Static Synchronous Series Compensators (M-SSSCs), enables dynamic voltage injection to reroute power flows. The session highlighted the deployment benefits of APFC, such as rapid installation, minimal civil works, and re-deployability. Regulatory drivers like FERC Order 2023 mandate the inclusion of Grid-Enhancing Technologies (GETs) in interconnection studies. Case studies from Central Hudson, CAISO, and National Grid (UK) demonstrated APFC’s effectiveness in congestion relief and cost savings. The session also addressed cybersecurity concerns, including firmware vulnerabilities, SCADA integration risks, and supply chain dependencies. Participants engaged in interactive exercises to rank cybersecurity and supply chain risks, emphasizing the need for robust digital assurance strategies. TTO involves software-based reconfiguration of transmission networks to optimize power flow without new infrastructure. The session showcased its operational value, with examples from SPP, PJM, and MISO showing significant congestion cost reductions. Cybersecurity vulnerabilities were discussed, particularly in API security and software supply chains, referencing incidents like SolarWinds and attacks on Danish utilities. Digital assurance exercises explored worst-case scenarios, attack paths, and mitigation responsibilities between vendors and utilities. Reliability challenges such as algorithm stability, vendor dependency, and operator trust were also examined. Cross-cutting themes emphasized the importance of digital assurance tools, including Software Bills of Materials (SBOMs) and hardware-in-loop testing. Human performance, training, and operational confidence were identified as critical enablers of technology adoption. The session concluded with a preview of Session 3, which will focus on High Performance Conductors (HPCs) and risk-based cybersecurity tools. Session 2 of 3.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRSDate not supplied

NASA’s Strategic Analysis Cycle 2021 (SAC21) Human Mars Architecture

[Note: this is the presentation for a companion paper with the following abstract] The National Aeronautics and Space Administration’s (NASA) Mars Architecture Team (MAT) was challenged to develop a mission architecture capable of transporting humans to the surface of Mars and back as fast—and as soon—as practical. This challenge represented a significant departure from previous approaches that minimized Earth-launched mass and maximized in-space transportation efficiency, often resulting in roundtrip missions of three years or more in duration. In the interest of crew health, MAT’s cross-Agency team of subject matter experts was challenged to develop an architecture capable of shortening crew time away from Earth to about two years. MAT was given specific mission constraints, such as number of crew, as well as mandates to minimize surface infrastructure as much as possible and to incorporate nuclear transportation options. The resulting MAT-developed concept, referred to here as the Strategic Analysis Cycle 2021 (SAC21) architecture, leverages Artemis elements and emerging commercial capabilities for cargo and logistics launches, and features a hybrid Nuclear Electric Propulsion (NEP)/Chemical transportation system able to complete the 1.8 billion kilometer round-trip journey to Mars and back in 760 to 850 days transit time for the 2039 Earth departure opportunity. Three Mars Descent Systems (MDS), each capable of landing about 25 metric tons of useful cargo on the surface of Mars, would be pre-deployed in advance of crew departure from Earth; two of these MDS’s would deliver a partially fueled Mars Ascent Vehicle (MAV), a fission power system, surface mobility, and additional MAV propellant. To minimize surface infrastructure, only two of the four Mars crew would descend and live in an MDS-landed pressurized rover, exploring the martian surface for 30 martian days, or sols, before returning to Mars orbit aboard their MAV and rejoining the other two crew on the Deep Space Transport for the Earth return voyage. Specifics of many of these architecture elements are detailed in separate technical publications; this paper outlines the end-to-end integrated architecture performance and concept of operations, including synergies with Artemis lunar architecture elements. It is important to note that NASA does not have a formal human Mars program and no decisions have been made; the architecture described here is intended to fill in an often-overlooked corner of the trade space, helping to complete the menu of options available to decision-makers as they chart the course for humans to Mars. Note: Slide 9 contains a ~2 min video, best viewed when downloaded. Once downloaded to begin video you may be requested to hit options and Trust this document.

Long-duration spaceflight↗
NASA NTRS2014

Collaborative WorkBench for Researchers - Work Smarter, Not Harder

It is important to define some commonly used terminology related to collaboration to facilitate clarity in later discussions. We define provisioning as infrastructure capabilities such as computation, storage, data, and tools provided by some agency or similarly trusted institution. Sharing is defined as the process of exchanging data, programs, and knowledge among individuals (often strangers) and groups. Collaboration is a specialized case of sharing. In collaboration, sharing with others (usually known colleagues) is done in pursuit of a common scientific goal or objective. Collaboration entails more dynamic and frequent interactions and can occur at different speeds. Synchronous collaboration occurs in real time such as editing a shared document on the fly, chatting, video conference, etc., and typically requires a peer-to-peer connection. Asynchronous collaboration is episodic in nature based on a push-pull model. Examples of asynchronous collaboration include email exchanges, blogging, repositories, etc. The purpose of a workbench is to provide a customizable framework for different applications. Since the workbench will be common to all the customized tools, it promotes building modular functionality that can be used and reused by multiple tools. The objective of our Collaborative Workbench (CWB) is thus to create such an open and extensible framework for the Earth Science community via a set of plug-ins. Our CWB is based on the Eclipse [2] Integrated Development Environment (IDE), which is designed as a small kernel containing a plug-in loader for hundreds of plug-ins. The kernel itself is an implementation of a known specification to provide an environment for the plug-ins to execute. This design enables modularity, where discrete chunks of functionality can be reused to build new applications. The minimal set of plug-ins necessary to create a client application is called the Eclipse Rich Client Platform (RCP) [3]; The Eclipse RCP also supports thousands of community-contributed plug-ins, making it a popular development platform for many diverse applications including the Science Activity Planner developed at JPL for the Mars rovers [4] and the scientific experiment tool Gumtree [5]. By leveraging the Eclipse RCP to provide an open, extensible framework, a CWB supports customizations via plug-ins to build rich user applications specific for Earth Science. More importantly, CWB plug-ins can be used by existing science tools built off Eclipse such as IDL or PyDev to provide seamless collaboration functionalities.

Ramachandran, Rahul↗
DOE OSTI2025

Can Restoring Tidal Wetlands Reduce Estuarine Nuisance Flooding of Coasts Under Future Sea‐Level Rise?

Wetland restoration is an increasingly popular nature‐based method for flood risk mitigation in coastal communities. In this study, we present a novel method using hydrodynamic modeling and harmonic analysis to quantify wetlands' ability to reduce future nuisance flooding. The method leverages a hydrodynamic model calibrated to present day data and was run for a range of future sea‐level rise (SLR) and wetland restoration scenarios to quantify changes to tidal harmonic amplitudes and phases. The harmonic constituents are used to generate water surface elevations over a time period of interest (e.g., one year) and compared to critical exceedance thresholds such as levee elevations. Then, changes to nuisance flooding are calculated by counting the number of hours critical thresholds are exceeded under different SLR and wetland restoration scenarios. We applied the method to Coos Bay, Oregon, USA as a test case. We found restoration reduces the number of hours nuisance flooding occurs in downtown Coos Bay from 15 hr (present day conditions) to 0 hr (fully restored condition) under median SLR (82 cm by 2100). Restoration had spatially variable impacts on reducing peak flood elevations with minimal impacts near the estuary mouth and greatest impact 32 km inland. The effectiveness of restoration was heavily dependent on future SLR. Restoration was maximally effective in 2050 under all SLR scenarios, less effective in 2100 under median SLR, and not effective under high SLR. Modeling results suggest increased tidal prism and accommodation space are driving restoration‐associated reductions in tidal amplitudes.

Brand, Matthew W. [Louisiana State Univ., Baton Ro↗
NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗