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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

SpiderFab: Process for On-Orbit Construction of Kilometer-Scale Apertures

The SpiderFab effort has investigated the value proposition and feasibility of radically changing the way we build and deploy spacecraft by enabling space systems to fabricate and integrate key components on-orbit. In this Phase II effort, we have focused on developing and demonstrating tools and processes to enable robotic systems to manufacture and assemble high performance structural elements that will serve as the support structures for components such as antennas and solar arrays. Through testing of these technologies in the laboratory environment,these efforts have established the technical feasibility of the key capabilities required for in-space manufacture of large apertures such as antennas, solar arrays, and optical systems,maturing prototype technical solutions for these capabilities to TRL-4. The SpiderFab effort has resulted in successful post-NIAC transition of the technology, first to SBIR-funded development of a technology for in-space manufacture (ISM) of truss structures, and then to a NASA/STMD Tipping Point Technologies funded effort to prepare a flight demonstration of ISM of a structure for a GEO communications satellite.

Manufacturing↗
NASA NTRS2019

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

lattice geometry↗
NASA NTRS2019

Preliminary Nonlinear Structural Analysis of Advanced Composite Tow-Steered Shells with Large Geometric Imperfections

The structural performance of two advanced composite tow-steered shells with and without tow overlaps, and with large geometric imperfections, are predicted using linear and geometrically nonlinear finite element analyses. These shells, 35 in. long and approximately 16.3 in. diameter, are fabricated using automated fiber placement from IM7/8552 graphite/epoxy prepreg. The 8-ply,[±45/±Θ]s. shell layup incorporates a steered fiber angle Θ that varies from 10 deg. to 45 deg. periodically over the shell circumference. Shell analysis models are evaluated using geometric imperfections normalized to ±1 shell wall thickness (±0.040 in.), which are then superposed and rotated incrementally around the shell longitudinal axis. Using these nominal imperfections, the shell prebuckling axial stiffnesses and buckling loads predicted with linear and nonlinear analyses are close to reference values from linear analyses with no imperfections. The linear and nonlinear analyses are then repeated for scaled imperfections that are larger by up to a factor of 10. For these larger imperfections, linear analyses predict reductions in axial stiffnesses and buckling loads of up to 5 and 30 percent, respectively, from reference values. The nonlinear analyses predict even larger reductions in axial stiffnesses and buckling loads of up to 10 and 55 percent, respectively.

Dobrin, Calvin P.↗
NASA NTRS2019

Developments on Low Cost Manufacturing Methods for Cylindrical Launch Vehicle Structures

Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.

Martin Stachulla↗
NASA NTRSDate not supplied

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

digital materials↗
NASA NTRSDate not supplied

TPSAS-NF1676L-32709-DND

Outline - Process-Structure-Performance Framework - Process-Specific Defects in selective laser melting (SLM) additive manufacturing (AM) process - Idealized Keyhole/Entrapped gas pores - Idealized Lack of Fusion (LoF) pores - Influence of Pore Geometry on Strain Localization - 3D Model of LoF pores - Partial validation of the 3D LoF 2 model

Saikumar R Yeratapally↗
NASA NTRSDate not supplied

Next Generation Durability and Damage Tolerance to Support Certification of Flight Hardware

Durability and Damage Tolerance (D&DT), as currently applied to flight hardware throughout the Agency, is based on continuum and similitude assumptions and does not consider local material properties, environments and responses. These limitations impact our ability to support certification of new component designs, material systems and manufacturing approaches. The primary concern in this Engineering R&A plan is related to the imminent proliferation of parts produced by additive manufacturing (AM). These parts are being advocated by NASA’s suppliers for use on a myriad of flight hardware because of their design flexibility and cost advantages. AM provides opportunities to reduce part counts through complex geometry and reduce manufacturing costs of low volume parts. However, AM materials have some notable metallurgical and microstructural differences compared to traditionally fabricated materials. One of the challenges for the acceptance of AM is the greater tendency for a deleterious defect state, most commonly in the form of porosity, to exist in AM parts. Though this defect state is typically reduced through a hot isostatic pressing (HIP) processing step, the structural performance risks associated with the remaining defects and HIP-healed features is not known. Potential fracture control issues that must be resolved stem from the real possibility that an unhealed defect or a closed defect with less than pristine strength remains at a fracture critical location after HIP. As a result, NASA and the entire aerospace community have been confronted with the need to develop a robust and relevant certification methodology to enable safe implementation of these components. The present work is an important step toward positioning NASA to credibly respond to vendors’ push to implement this new AM materials technology by improving our understanding of AM processing and performance and transitioning that research-based understanding to next-generation engineering capabilities.

Edward H Glaessgen↗
NASA NTRSDate not supplied

Lessons Learned from Large-Scale Aerospace Structural Testing

Large-scale testing of aerospace structures is frequently the final step in a development project to validate the structural performance, and that typically involves a large cost and time investment. In order to ensure that the testing provides the required data, avoiding errors that can result in an unsuccessful test and failure to meet objectives is critical. Presented herein are five lessons learned to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five subject large-scale tests are described, and include two composite wing tests, a composite hybrid-wing body center section test, a full-scale 27.5-ft diameter metallic barrel test, and an 8-ft diameter metallic barrel test. Problems identified during the testing and mitigation approaches to solve the problems are presented, then the lessons learned are summarized.

Lessons Learned↗
NASA NTRSDate not supplied

Lessons Learned from Large-Scale Aerospace Structural Testing

Large-scale testing of aerospace structures is frequently the final step in a development project to validate the structural performance, and that typically involves a large cost and time investment. In order to ensure that the testing provides the required data, avoiding errors that can result in an unsuccessful test and failure to meet objectives is critical. Presented herein are five lessons learned to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five subject large-scale tests are described, and include two composite wing tests, a composite hybrid-wing body center section test, a full-scale 27.5-ft diameter metallic barrel test, and an 8-ft diameter metallic barrel test. Problems identified during the testing and mitigation approaches to solve the problems are presented, then the lessons learned are summarized.

Lessons Learned↗
NASA NTRSDate not supplied

Playing with DIRT: Building the Framework for a Comprehensive In-Situ Soil Materials Testing Database

Long-term, sustainable planetary exploration will require the ability to "live off the land," relying on In-Situ Resource Utilization (ISRU) and In-Situ Construction as core capabilities. Reduction of both risk and launch mass for lunar construction will require evaluating and comparing regolith materials for use as feedstocks suitable for in-situ beneficiation and fabrication of building components. These material assessment capabilities will inform lunar infrastructure design decisions, with co-benefits for terrestrial construction using in-situ materials. Current planetary construction technology development relies on lunar mapping and orbital data, Apollo-era sample analyses, current simulant inventories, and tests conducted using analog site soils. Requirements for lunar infrastructure design decisions and construction systems will be determined based on specific environmental conditions, mission architectures, and the materials available within traverse range of lunar feedstock processing depots. Critical for success is the capability to identify, evaluate and make effective use of a wide range of materials as they are found in-situ on the lunar surface. This paper discusses the development of a digital repository for data on soil and regolith properties, beginning with their structural performance in both cementitious and non-cementitious building material formulations. The Database for In-situ Resource Testing (DIRT) compiles a catalog of raw materials, additives, and formulations, with notations pertaining to material sources and preparation techniques entered via a web-based user interface. Design of consistent data schemas for site-sourced materials evaluation will facilitate linkage with relevant terrestrial and planetary materials databases while enabling guided data input via templates for participation by broader groups of collaborators. Results of these analyses are compiled in a centralized repository to generate insights applicable for regolith resources and landing sites yet to be precisely defined. Collection of thorough records of material characteristics, applications and performance will support innovative construction solutions not only for space infrastructure but for sustainable, resilient design in the terrestrial built environment.

Sarah Joey Seitz↗
NASA NTRSDate not supplied

Generative Design and Digital Manufacturing: Using AI and Robots to Build Lightweight Instruments

Digital Engineering technologies are transforming long-stagnant development processes by applying the tremendous advancements in Information Technology (IT) to classical engineering tasks such as design, analysis, and fabrication of space-flight instrument structures. Generative Design leverages developments in Artificial Intelligence (AI) and Cloud computing to enable a paradigm shift in the design process, allowing the engineer to focus on defining the requirements and objectives of the design while AI generates optimized designs which comply with the input requirements. Digital Manufacturing allows these complex lightweight designs to be efficiently manufactured by directly fabricating from the resulting 3D models. The development of these two Digital Engineering technologies realizes significant mass savings while simultaneously reducing structure development time from months to days. This paper describes the development of the Evolved Structures process applying these technologies to spaceflight optical instrument structures including an example demonstrating greater than 10x reduction in development time/cost and greater than 3x improvement in structural performance.

Ryan McClelland↗
NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗
NASA NTRS2026

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification↗
DOE OSTI2024

Ultrahigh Performance Metallic Turbine Blades for Extreme Environments

In ULTIMATE Phase-I, The Boeing Company and Alloyed Inc. aimed to produce ultrahigh performance metallic extreme environment turbine blades with a base blade alloy capable of inert operation at 1300C, and a maximum coated blade operating temperature up to 1800C. High-performance structural designs for extreme service conditions place additional demands on the present material capability and can potentially outpace the current state-of-the-art in the alloy design space and metal processing. As a part of exploration and adoption of novel concepts for material maturation, the team explored a series of capable base novel refractory complex concentrated alloy (RCCA) compositions and potential powder enhancements. Advanced manufacturing processes, with a focus on laser powder bed fusion additive manufacturing (AM) and powder metallurgy (PM) approaches, were applied to consolidate new alloys and for near net shape processing of blades from the base RCCA.

Yousefiani, Ali↗
NASA NTRS1989

Experimental studies of adaptive structures for precision performance

An experimental study was made of the adaptive structure concept. Experimental data were obtained for a three-longeron, thirteen-bay truss-type test structure. This test structure can be softly suspended as well as rigidly clamped at the central bay. The load-carrying active member consists of a stack of concentric piezoelectric wafers, an eddy current displacement sensor, and a strain gage force sensor. A bridge (or compound) feedback technique developed in communication engineering is applied to the problem of active damping augmentation in adaptive structures. Using collocated force and velocity feedback around the active member, a desired output mechanical impedance can be implemented to maximize energy absorption by the active members. In addition, large gains can be implemented to linearize the active member's nonlinear behavior. Good agreements with linear finite element analysis was found for both static and dynamic structural responses. An 11 percent damping in the first bending mode was demonstrated in the closed-loop damping experiment.

Chen, G.-S.↗
DOE OSTI2020

Modernization of Technical Requirements for Licensing of Advanced Non-Light Water Reactors: Safety Classification and Performance Criteria for Structures, Systems, and Components

This report, “Modernization of Technical Requirements for Licensing of Advanced Non-Light Water Reactors: Safety Classification and Performance Criteria for Structures, Systems and Components,” represents a key element in the development of a framework for the efficient licensing of advanced non-Light Water Reactors (non-LWRs). It is the result of a Licensing Modernization Project (LMP) led by Southern Company and cost-shared by the United States Department of Energy (DOE).

42 ENGINEERING↗
DOE OSTI2021

Cu-Local Structures and Their Relation with Nanoscale Electrical Performance in CdTe

For decades, copper has been introduced in CdTe devices to improve overall performance (open circuit voltage, fill factor, and series resistance). While multiple articles have reported on Cu-based defects, very little is known about how the local structure around the copper atom affects electrical performance. Using X-ray Absorption Near Edge Structure (XANES) coupled with X-ray microscopy we investigate good and poor performing region in Cu-doped CdTe devices. Our XANES coupled with theoretical standards by FEFF9 suggest that CU 2 Te phase and Cu Cd may be responsible for the high electrical performance of the regions under study. This correlation of structure-performance at the nanoscale offers a unique framework to understand and tune processes with deep implications to the overall electrical performance of the solar cell.

CdTe↗
DOE OSTI2024

Hard carbon with an opened pore structure for enhanced sodium storage performance

The pore structure of hard carbon has a significant impact on its Na + storage capacity. Herein, a waste wood-derived hard carbon with opened pores (OP-HC) was fabricated with polyvinyl pyrrolidone (PVP) as an additive. Ex situ SAXS and HR-TEM testing results indicate that OP-HC with opened pores and enlarged d 002 interlayer spacing facilitates the reversible (de)sodiation of Na + ions. In situ TEM and XRD testing results demonstrate that OP-HC shows excellent structure stability during the (de)sodiation process. Thus, OP-HC delivers a high reversible charge capacity of 350.7 mA h g −1 at 0.05 C and an ultra-high initial Coulombic efficiency (ICE) of 94.9%. Moreover, OP-HC exhibits excellent cycling stability, and the assembled 18650 full cell with an OP-HC anode can achieve a high capacity retention of 94.5% after 400 cycles at 1.0 A. Furthermore, the excellent electrochemical performance and deep insights into OP-HC with opened pores and increased d 002 interlayer spacing offer a new strategy to design high-performance HC anodes for SIBs.

You, Shunzhang↗