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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Real-Time Acoustic Analysis of Batteries

The project explored development and commercialization of an acoustical approach to battery diagnostics. The technology has significant potential impacts for battery manufacturing and quality assurance, battery management during operation, and could be an enabler for the second-life battery market. Research was focused on inspecting and analyzing the physical condition of batteries using ultrasound. This consisted of designing and building hardware for gathering high-quality acoustic data, as well as using battery charge-discharge cyclers and temperature chambers to operate and age the batteries. Over the course of the 2-year program, we were able to build our first prototypes that are robust enough to be used by industry partners to evaluate our technology. Using the same prototypes, we also showed preliminary evidence that our acoustic inspection method may have distinct advantages over standard electrical methods in terms of detecting differences in the physical quality of battery cells. The project also expanded the participant’s core capabilities beyond time-of-flight acoustic measurements.

25 ENERGY STORAGE↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Dynamics Questions Associated with the AERCam Sprint Free-Flyer

The International Space Station will require the development of small robotic vehicles for such tasks as external inspection, monitoring of extravehicular activities (EVA's) and station build-up, and providing additional lighting at EVA worksites. The Autonomous EVA Robotic Camera (AERCam) family of free-flyers is currently being developed at NASA Johnson Space Center to perform these functions; the first member of the family is the AERCam Sprint vehicle. Many interesting dynamical questions are associated with the Sprint free-flyer. For instance, the reaction of a vehicle which is nearly spherically symmetric (such as Sprint) to a stuck-on thruster is significantly more complicated than that obtained for an idealized, perfectly spherical, spacecraft model. In particular, the real spacecraft will experience a form of forced nutation, with convergence towards either its major or minor principal axis, depending on both the applied torque and the mass properties of the vehicle. Furthermore, the body-fixed jet force vector may have a significant component along this principal axis, so giving rise to a considerable net linear acceleration of the spacecraft. The large velocity that can result is very important, as it may lead to collision with the nearby Orbiter, and is completely overlooked in the idealized analysis. This report will firstly briefly describe the stuck-on thruster dynamics of the real vehicle, and outline how the small products of inertia of the spacecraft determine the time constants of the motion. Secondly, the dynamical effects of a failed-off jet on the Sprint free-flyer will be described in more detail, and compared with the stuck-on thruster case. This will help to show whether the two malfunctions should be dealt with differently in flight. Finally, the stuck-on thruster detection software (known as the uncommanded motion algorithm) that is proposed to be flown on the Sprint vehicle will be analyzed, and all possible perturbation sources that may tend to give rise to false stuck-on thruster alarms quantified. It will be shown that false alarms can be triggered by discrete events such as a failed-off thruster, a glancing collision with Orbiter structure, or thruster saturation. They can also be triggered by a combination of errors introduced by constantly present sources such as thrust level errors, thruster misalignment, inertial cross-coupling, angular rate sensor noise, and structural vibrations induced by thruster firings. Based on this fact, the original plan to have the spacecraft enter safe mode whenever the uncommanded motion algorithm is triggered does not appear to be advisable. A better approach seems to be to provide the Sprint pilot with a warning whenever uncommanded motion is detected, and then allow the crew to determine whether safing the vehicle is appropriate.

Williams, Trevor↗
DOE OSTI2026

MCP-enabled agentic AI workflow for building energy modelling: framework and use cases

Traditional building energy modelling workflows remain labor-intensive and error-prone, requiring specialized expertise that limits broader adoption. This paper introduces a novel Model Context Protocol (MCP)-enabled framework that connects AI assistants to EnergyPlus through MCP, a standardized interface for tool invocation and context management. Two complementary integration paradigms are presented and compared: conversational integration, where users interact through natural language while an AI assistant orchestrates MCP tools on demand, and agentic workflow integration, where specialized agents coordinate autonomously to complete multi-step tasks. Using an experimental testbed for residential buildings, the end-to-end workflows are demonstrated. The conversational approach reduced typical inspection and modification tasks from 1-2 h to under 15 min, while maintaining full transparency through visible tool invocations. The agentic approach automated parametric analysis. These demonstrations establish MCP as a foundational layer for AI-assisted building energy modelling, enabling natural language interactions with simulation tools while preserving professional oversight and decision-making authority.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2004

Development of Columbia Leading Edge Reconstruction System

After the loss of Columbia in 2003, the Columbia Accident Investigation Board and NASA KSC directed personnel at the Launch Equipment Test Facility (LETF) to design and build high fidelity mock-ups of Columbia's left wing leading edges. These leading edge segments, constructed of reinforced carbon-carbon, were a major point of inquiry by the investigation team. The LETF engineers developed a concept of building a clear Lexan panel with an aluminum support structure ten percent larger than the original panel. The leading edge debris are attached to the Lexan panels and both the front and back side of each panel are visible for inspection. The entire assembly can be rotated, to provide visual access to the entire panel. Six carts were fabricated to support the thirteen panels. These carts could be set up in order, next to each other, to provide the desired inspection access. The carts and attached debris are currently located in the Vehicle Assembly Building at KSC.

Trautwein, John↗
DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗
DOE OSTI2026

1016516285-AA - Handling Frame Assembly Table Structural and Seismic Analysis

Within the NIF (National Ignition Facility) sustainment project, LLNL is replacing all 1,728 blast shields with new ones. Before the new blast shield glass can be installed on NIF, it must pass through the AMOL (Amplifier Main Optics Loop). The AMOL process involves cleaning and coating the glass, assembling it into a Line Replaceable Unit (LRU), and performing testing and inspection. This work will be conducted in the OPFX cleanroom facility (Building 391, Room 1250) and requires several pieces of custom equipment. One key piece of equipment within the loop is the Handling Frame Assembly Table (see Figure 1.1). Its purpose is to assist operators in installing the blast shield glass into handling frames (1014442709) (see Figure 1.2). The table is also used to store handling frame assembly components. The primary components stored are the L-frames (1015208271), which are kept in a drawer underneath the table (see Figure 1.3). The purpose of this safety note is to ensure that the system does not pose a risk of injury to personnel during a seismic event. The system owner is OMST Engineering & Maintenance.

42 ENGINEERING↗
NASA NTRS2009

Defect Depth Measurement Using White Light Interferometry

The objectives of the White Light Interferometry project are the following: (1) Demonstrate a small hand-held instrument capable of performing inspections of identified defects on Orbiter outer pane window surfaces. (2) Build and field-test a prototype device using miniaturized optical components. (3) Modify the instrument based on field testing and begin the conversion of the unit to become a certified shop-aid.

Parker, Don↗
NASA NTRS1984

Guidelines for testing and release procedures

Guidelines and procedures are recommended for the testing and release of the types of computer software efforts commonly performed at NASA/Ames Research Center. All recommendations are based on the premise that testing and release activities must be specifically selected for the environment, size, and purpose of each individual software project. Guidelines are presented for building a Test Plan and using formal Test Plan and Test Care Inspections on it. Frequent references are made to NASA/Ames Guidelines for Software Inspections. Guidelines are presented for selecting an Overall Test Approach and for each of the four main phases of testing: (1) Unit Testing of Components, (2) Integration Testing of Components, (3) System Integration Testing, and (4) Acceptance Testing. Tools used for testing are listed, including those available from operating systems used at Ames, specialized tools which can be developed, unit test drivers, stub module generators, and the use of format test reporting schemes.

Molari, R.↗
NASA NTRS2010

Principal Components Analysis of Reflectance Spectra Returned by the Mars Exploration Rover Opportunity

The Mars Exploration Rover Opportunity has spent over six years exploring the Martian surface near its landing site at Meridiani Planum. Meridiani bedrock observed by the rover is largely characterized by sulfate-rich sandstones and hematite spherules, recording evidence of ancient aqueous environments [1]. The region is a deflationary surface, allowing hematite spherules, fragments of bedrock, and "cobbles" of foreign origin to collect loosely on the surface. These cobbles may be meteorites (e.g., Barberton, Heat Shield Rock, Santa Catarina) [2], or rock fragments of exotic composition derived from adjacent terranes or from the subsurface and delivered to Meridiani Planum as impact ejecta [3]. The cobbles provide a way to better understand Martian meteorites and the lithologic diversity of Meridiani Planum by examining the various rock types located there. In the summer of 2007, a global dust storm on Mars effectively disabled Opportunity's Miniature Thermal Emission Spectrometer (Mini-TES), which served as the Athena Science Team s primary tool for remotely identifying rocks of interest on a tactical timescale for efficient rover planning. While efforts are ongoing to recover use of the Mini-TES, the team is currently limited to identifying rocks of interest by visual inspection of images returned from Opportunity's Panoramic Camera (Pancam). This study builds off of previous efforts to characterize cobbles at Meridiani Planum using a database of reflectance spectra extracted from Pancam 13-Filter (13F) images [3]. We analyzed the variability of rock spectra in this database and identified physical characteristics of Martian rocks that could potentially account for the observed variance. By understanding such trends, we may be able to distinguish between rock types at Meridiani Planum and regain the capability to remotely identify locally unique rocks.

Mercer, C. M.↗
NASA NTRSDate not supplied

Making & Breaking the Rules for DED Design

Design for Additive Manufacturing (DfAM) is widely used to describe design activities and guidelines employed in the creation of Additively Manufactured (AM) parts. Basic design rules for widely adopted processes like Powder Bed Fusion (PBF) are relatively understood including material performance, part size constraints, self-supporting angles, overhangs, wall thicknesses, and feature resolution. Complexity is often inherent with PBF using organically inspired solutions through generative design and topology optimization software to create designs that often cannot be realized via traditional manufacturing processes. The design rules for Directed Energy Deposition (DED) are less well known, and, in some cases, the lack of understanding is likely inhibiting broader application of the various DED processes. This presentation covers key design rules for DED fusion processes and elucidates opportunities like multi-material deposition and build approaches ranging from basic features to complex large-scale parts. Complementary to the opportunistic characteristics of DfAM for DED, Manufacture for AM (MfAM) encompasses the restrictive aspects of the manufacturing lifecycle with limitations due to bead width and wall thickness, self-supporting angles, surface texture, microstructural evolution, and residual stresses. AM enabled part design must always consider the entire value chain starting with incoming feedstock (e.g. plate, wire, or powder) and progressing through the printing process, post-processing (e.g. machining, inspection), and final system assembly. Key considerations, like the tradeoffs between feature resolution and build rate, for process and part selection and economic assessments will be discussed as DED is often traded against other AM processes. After highlighting typical DED design rules, we will also show how some of those rules can be broken via use cases and part designs that span the full spectrum of DED processes with examples of various DED part designs.

Additive Manufacturing↗
DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Building ControlScore: General Service Administration Office Building Deployment

Improvements to building control systems can lead to energy savings and increased occupant comfort. In an optimized system, process variables such as air temperature will closely follow their desired setpoints and avoid excess energy use. Typically, experts must manually inspect individual control loops to identify poor performance and opportunities for improvement. However, this approach is difficult in modern buildings that have a prohibitively large number of controllers. To address this issue, Pacific Northwest National Laboratory (PNNL) created the ControlScore concept, which takes operating data from the many controllers within a building and generates standardized scores for each loop on a scale of 0 to 10 (a score of 0 indicates poor control, a score of 10 indicates good control). PNNL applied the Building ControlScore application to all available data from a General Services Administration office building within the period of January 1, 2023, to March 9, 2023. The building scored a 4.7 overall, with all 74 of the building’s loops fitting a roughly normal distribution centered around 5. These results indicate that the analyzed systems have below-average performance with room for improvement, especially in the poorly scored systems. Airflow loops tended to have much lower scores than zone temperature loops. The lowest and highest performing systems in the building section were identified, as were all loops with a score less than 1. While the ControlScore identifies loops and systems that aren’t meeting their designated setpoints, it does not indicate the cause of those issues. For example, consider a supply air terminal unit’s airflow loop that received a low score due to it delivering less air than specified by the setpoint. The lower-than-desired airflow could be due to equipment limitations (e.g., the terminal unit or duct serving is too small to accommodate that airflow), malfunctioning equipment (e.g., a stuck damper or bad sensor), or something else entirely. The ControlScore does not diagnose problems it simply identifies the symptoms that can be explored and addressed by building operators.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Building ControlScore: Research Laboratory Building Deployment

Improvements to building control systems can lead to energy savings and increased occupant comfort. In an optimized system, process variables such as air temperature will closely follow their desired setpoints and avoid excess energy use. Typically, experts must manually inspect individual control loops to identify poor performance and opportunities for improvement. However, this approach is difficult in modern buildings that have a prohibitively large number of controllers. To address this issue, Pacific Northwest National Laboratory (PNNL) created the ControlScore tool which captures operating data from the many controllers within a building and generates standardized scores for each loop on a scale of 0 to 10 (a score of 0 indicates poor control, a score of 10 indicates good control).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1989

Manufacturing Aids

During a research program, MMTC/Textron invented a computer-aided automatic robotic system for spraying hot plasma onto a turbine blade. The need to control the thickness of the plasma deposit led to the development of advanced optical gaging techniques to monitor and control plasma spray build-up on blade surfaces. The techniques led to computerized optical gages for inspecting aircraft, industrial turbine blades, etc. MMTC offers 10 standard commercial robotic gages. The system also generates two dimensional profiles for assessing status and specifying repairs to the electromechanical cathodes used to make the parts. It is capable of accuracies to a ten-thousandth of an inch. An expanded product line is currently marketed. The gages offer multiple improvements in quality control and significant savings.

Source record↗
NASA NTRS2005

STS-114: Discovery Tanking Operations for Launch

Jessica Rye from NASA Public Affairs is the narrator for the tanking operations for the launch of the Space Shuttle Discovery. She presents a video of the arrival and processing of the new external tank at the Kennedy Space Center. The external tank is also shown entering the Vehicle Assembly Building (VAB). The external tank underwent new processing resulting from its redesign including inspection of the bipod heater and the external separation camera. The changes to the external tank include: 1) Electric heaters to protect from icing; and 2) Liquid Oxygen feed line bellows to carry fuel from the external tank to the Orbiter. Footage of the external tank processing facility at NASA's Michoud Assembly Facility in New Orleans, La. prior to its arrival at Kennedy Space Center is shown and a video of the three key modifications to the external tank including the bipod, flange and bellows are shown.

Source record↗
DOE OSTI2021

Effects of Build Orientation and Heat Treatment on Neutron Irradiation Hardening in Inconel 625 Fabricated via Laser Powder Bed Fusion

Various Inconel 625 coupons fabricated via Laser Powder Bed Fusion (L-PBF) were neutron irradiated using the inside reflector of the reactor at the University of Missouri Research Reactor (MURR). Effects of build orientation and heat treatment on neutron-induced hardening were investigated by inspecting L-PBF samples built vertically or at a 45º angle in the following heat-treated conditions: as-built (no heat treatment), 700 ºC for 1 hour, 900 ºC for 1 hour, and 1050 ºC for 1 hour. The microhardness results of L-PBF samples before and after neutron irradiation were compared with traditional wrought Inconel 625. All samples underwent an irradiation flux of 6.61 x 1013 neutrons/cm²/s for 310 hours for an estimated damage of 0.012 dpa. Results indicate that as-built L-PBF specimens are less prone to radiation hardening relative to their wrought counterparts. As-printed diagonal specimens were shown to harden by 8% as compared to 1.2% hardening in as-printed vertical specimens.

36 MATERIALS SCIENCE↗