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At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Genesis of a novel high-rate composite manufacturing process using large-scale additive manufacturing – compression molding (AM-CM) system: Possibilities and limitations

Oak Ridge National Laboratory (ORNL) has developed a highly automated manufacturing process for thermoplastic composites that combines the benefits of Additive Manufacturing and Compression Molding (AM-CM) to produce high-performance functional composite structures at automotive production rates. Here, the AM-CM process creates highly precise preforms by additively placing extruded fiber-filled polymers (with controlled fiber orientations and multi-material configurations) in the desired mold location before undergoing a secondary compression molding process immediately before the preform cools down. Preforms can be in the form of short, long-chopped, or continuous fiber-filled thermoplastic polymers (e.g., CF/GF-filled ABS, PC, LM-PAEK, etc.). The AM-CM process combines the benefits of controlled fiber alignment, that is only achievable in AM-printed parts with the classical CM process, which eliminates porosity and good surface finish. A preform created using AM-CM can integrate various materials to enable additional architectural functionalities, including over-molding, selective stiffening, and the incorporation of electrically or thermally conductive channels. All these advantages come with a fast part production cycle time. The AM-CM process can manufacture multi-material, multi-functional parts in under 3 min, starting from raw material (pellets) to the final product. The novel AM-CM process offers superior microstructural control and enhanced multi-functionality previously unattainable with any other traditional high-rate thermoplastic composite manufacturing method. This work covers the manufacturing concept, system development, materials and applications of AM-CM process in detail.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2021

Shock compression response of additively manufactured AlSi10Mg

We measured the Hugoniot, Hugoniot elastic limit (HEL), and spallation strength of laser powder bed fusion (LPBF) AlSi10Mg via uniaxial plate-impact experiments to stresses greater than 13 GPa. Despite its complex anisotropic microstructure, the LPBF AlSi10Mg did not exhibit significant orientation dependence or sample-to-sample variability in these measured quantities. We found that the Hugoniot response of the LPBF AlSi10Mg is similar to that of other Al-based alloys and is well approximated by a linear relationship: u s = 5.49 + 1.39u p . Additionally, the measured HELs ranged from 0.25 to 0.30 GPa and spallation strengths ranged from 1.16 to 1.45 GPa, consistent with values reported in other studies of LPBF AlSi10Mg and Al-based alloys. Furthermore, strain-rate and stress dependence of the spallation strength were also observed.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Engineering mechanical and thermomechanical performance in additive manufacturing–Compression molded composites through multiplexed extrusion

Traditional extrusion-based additive manufacturing is limited to single material systems, restricting the multifunctional properties of composites. For this work to overcome this limitation, multiplexed additive manufacturing–compression molding (AM-CM) was employed to fabricate multi-material thermoplastic composites with spatially tailored architectures. Neat acrylonitrile butadiene styrene (ABS) and 20 wt% carbon-fiber reinforced ABS (CF-ABS) were co-extruded through a core–sheath nozzle to produce hybrid composites with neat ABS as sheath (30-50 wt%) and CF-ABS as core (50 – 70 wt%). The results show that the hybrid composites have balance of mechanical and thermomechanical performance. The tensile strength and modulus of hybrid composites exhibited a 61–95% and 173–473% increase compared to neat ABS with increases in CF-ABS content whereas the impact resistance improved by 41% compared to CF-ABS at 50 wt% ABS. Additionally, hybrid composites showed significant reduction (54 - 70%) in creep strain at 100 °C compared to neat ABS. These findings demonstrate that multiplexed AM-CM enables tunable structure–property relationships, reducing CF-ABS usage up to 50 wt% while maintaining balanced stiffness, toughness, and creep resistance.

Additive manufacturing↗

NASA NTRS1988

Composite transport wing technology development: Design development tests and advanced structural concepts

Numerous design concepts, materials, and manufacturing methods were investigated for the covers and spars of a transport box wing. Cover panels and spar segments were fabricated and tested to verify the structural integrity of design concepts and fabrication techniques. Compression tests on stiffened panels demonstrated the ability of graphite/epoxy wing upper cover designs to achieve a 35 percent weight savings compared to the aluminum baseline. The impact damage tolerance of the designs and materials used for these panels limits the allowable compression strain and therefore the maximum achievable weight savings. Bending and shear tests on various spar designs verified an average weight savings of 37 percent compared to the aluminum baseline. Impact damage to spar webs did not significantly degrade structural performance. Predictions of spar web shear instability correlated well with measured performance. The structural integrity of spars manufactured by filament winding equalled or exceeded those fabricated by hand lay-up. The information obtained will be applied to the design, fabrication, and test of a full-scale section of a wing box. When completed, the tests on the technology integration box beam will demonstrate the structural integrity of an advanced composite wing design which is 25 percent lighter than the metal baseline.

Griffin, Charles F.↗

NASA NTRS1947

Knock-Limited Performance of Triptane and 28-R Fuel Blends as Affected by Changes in Compression Ratio and in Engine Operating Variables

A knock-limited performance investigation was conducted on blends of triptane and 28-P fuel with a 12-cylinder, V-type, liquid-cooled aircraft engine of 1710-cubic-inch displacement at three compression ratios: 6.65, 7.93, and 9.68. At each compression ratio, the effect of changes in temperature of the inlet air to the auxiliary-stage supercharger and in fuel-air ratio were investigated at engine speeds of 2280 and. 3000 rpm. The results show that knock-limited engine performance, as improved by the use of triptane, allowed operation at both take-off and cruising power at a compression ratio of 9.68. At an inlet-air temperature of 60 deg F, an engine speed of 3000 rpm ; and a fuel-air ratio of 0,095 (approximately take-off conditions), a knock-limited engine output of 1500 brake horsepower was possible with 100-percent 28-R fuel at a compression ratio of 6.65; 20-percent triptane was required for the same power output at a compression ratio of 7.93, and 75 percent at a compression ratio of 9.68 allowed an output of 1480 brake horsepower. Knock-limited power output was more sensitive to changes in fuel-air ratio as the engine speed was increased from 2280 to 3000 rpm, as the compression ratio is raised from 6.65 to 9.68, or as the inlet-air temperature is raised from 0 deg to 120 deg F.

Brun, Rinaldo J.↗

NASA NTRS1972

Compression of transmission bandwidth requirements for a certain class of band-limited functions.

A study of source-encoding techniques that afford a reduction of data-transmission rates is made with particular emphasis on the compression of transmission bandwidth requirements of band-limited functions. The feasibility of bandwidth compression through analog signal rooting is investigated. It is found that the N-th roots of elements of a certain class of entire functions of exponential type possess contour integrals resembling Fourier transforms, the Cauchy principal values of which are compactly supported on an interval one N-th the size of that of the original function. Exploring this theoretical result, it is found that synthetic roots can be generated, which closely approximate the N-th roots of a certain class of band-limited signals and possess spectra that are essentially confined to a bandwidth one N-th that of the signal subjected to the rooting operation. A source-encoding algorithm based on this principle is developed that allows the compression of data-transmission requirements for a certain class of band-limited signals.

Smith, I. R.↗

NASA NTRS2022

Astronaut Kinematics and Injury Risk for Piloted Lunar Landings and Launches While Standing

During future lunar missions, astronauts may be required to pilot vehicles while standing, and the associated kinematic and injury response is not well understood. In this study we used human body modeling to predict unsuited astronaut kinematics and injury risk for piloted lunar launches and landings in the standing posture. Three pulses (2-5 g; 10–150 ms rise times) were applied in 10 directions (vertical; ± 10-degree offsets) for a total of 30 simulations. Across all simulations, motion envelopes were computed to quantify displacement of the astronaut’s head (max 9.0 cm forward, 7.0 cm backward, 2.1 cm upward, 7.3 cm downward, 2.4 cm lateral) and arms (max 25 cm forward, 35 cm backward, 15 cm upward, 20 cm downward, 20 cm lateral). All head, neck, lumbar, and lower extremity injury metrics were within NASA’s tolerance limits, except tibia compression forces (0–1543 N upper tibia; 0–1482 N lower tibia; tolerance—1350 N) and revised tibia index (0.04–0.58 upper tibia; 0.03–0.48 lower tibia; tolerance—0.43) for the 2.7 g/150 ms pulse. Pulse magnitude and duration contributed over 80% to the injury metric values, whereas loading direction contributed less than 3%. Overall, these simulations suggest piloting a lunar lander vehicle in the standing posture presents a low risk of injury to the astronaut, although risk of tibia injury is potentially outside NASA’s acceptance limits and warrants further investigation.

Mitesh Lalwala↗

NASA NTRS1975

ITOS VHRR on-board data compression study

Data compression methods for ITOS VHRR data were studied for a tape recorder record-and playback application. A playback period of 9 minutes was assumed with a nominal 18 minute record period for a 2-to-1 compression ratio. Both analog and digital methods were considered with the conclusion that digital methods should be used. Two system designs were prepared. One is a PCM system and the other is an entropy-coded predictive-quantization, sometimes called entropy-coded DPCM or just DPCM, system. Both systems use data management principles to transmit only the necessary data. Both systems use a medium capacity standard tape recorder from specifications provided by the technical officer. The 10 to the 9th power bit capacity of the recorder is the basic limitation on the compression ratio. Both systems achieve the minimum desired 2 to 1 compression ratio. A slower playback rate can be used with the DPCM system due to a higher compression factor for better link performance at a given CNR in terms of bandwidth utilization and error rate. The report is divided into two parts. The first part summarizes the theoretical conclusions of the second part and presents the system diagrams. The second part is a detailed analysis based upon an empirically derived random process model arrived at from specifications and measured data provided by the technical officer.

Gray, R. M.↗

NASA NTRS1991

Low cost space power generation

The success of this study has given a method of fabricating durable copolymer films without size limitations. Previously, only compression molded samples were durable enough to generate electrical energy. The strengthened specimens are very long lived materials. The lifetime was enhanced at least a factor of 1,300 in full pyroelectric conversion cycle experiments compared with extruded, non-strengthened film. The new techniques proved so successful that the lifetime of the resultant copolymer samples was not fully characterized. The lifetime of these new materials is so long that accelerated tests were devised to probe their durability. After a total of more than 67 million high voltage electrical cycles at 100 C, the electrical properties of a copolymer sample remained stable. The test was terminated without any detectable degradation to allow for other experiments. One must be cautious in extrapolating to power cycle performance, but 67 million electrical cycles correspond to 2 years of pyroelectric cycling at 1 Hz. In another series of experiments at reduced temperature and electrical stress, a specimen survived over one-third of a billion electrical cycles during nearly three months of continuous testing. The radiation-limited lifetimes of the copolymer were shown to range from several years to millions of years for most earth orbits. Thus, the pyroelectric copolymer has become a strong candidate for serious consideration for future spacecraft power supplies.

Olsen, Randall B.↗

DOE OSTI2025

FedCSpc: A Cross-Silo Federated Learning System With Error-Bounded Lossy Parameter Compression

Cross-Silo federated learning is widely used for scaling deep neural network (DNN) training over data silos from different locations worldwide while guaranteeing data privacy. Communication has been identified as the main bottleneck when training large-scale models due to large-volume model parameters and gradient transmission across public networks with limited bandwidth. Most previous works focus on gradient compression, while limited work tries to compress parameters that can not be ignored and extremely affect communication performance during the training. Here, to bridge this gap, we propose FedCSpc: an efficient cross-silo federated learning system with an XAI-driven adaptive parameter compression strategy for large-scale model training. Our work substantially differs from existing gradient compression techniques due to the distinct data features of gradient and parameter. The key contributions of this paper are fourfold. (1) Our designed FedCSpc proposes to compress the parameter during the training using the state-of-the-art error-bounded lossy compressor – SZ3. (2) We develop an adaptive compression error bound adjustment algorithm to guarantee the model accuracy effectively. (3) We exploit an efficient approach to utilize the idle CPU resources of clients to compress the parameters. (4) We perform a comprehensive evaluation with a wide range of models and benchmarks on a GPU cluster with 65 GPUs. Results show that FedCSpc can achieve the same model accuracy as FedAvg while reducing the data volume of parameters and gradients in communication by up to 7.39× and 288×, respectively. With 32 clients on a 4 Gb size model, FedCSpc significantly outperforms FedAvg in wall-clock time in the emulated WAN environment (at the bandwidth of 1 Gbps or lower without loss of generality).

SZ3↗

DOE OSTI2023

Transition in helium bubble strengthening of copper from quasi-static to dynamic deformation

Damage from low-temperature irradiation and the subsequent degradation of materials performance pose significant challenges for the storage of radioactive materials and for peripheral components in some nuclear reactor designs. Fully understanding the mechanical behavior of such materials requires test data for strain rates in both the quasi-static (< 10/s) and dynamic (>> 10/s) regimes. While dynamic testing has generally been avoided in the past for neutron irradiated (contamination concerns) and ion irradiated (insufficient volume) materials, surface-sensitive Richtmyer-Meshkov instability (RMI) tests were used in the present work to overcome these limitations. Here, nanopillar compression, nanoindentation, and RMI testing data from a helium implanted surface layer (~10 µm thick) were compiled to explore the effects of helium bubbles on the materials strength of high-purity copper at strain rates of 0.001/s – 10 8 /s. While nano-mechanical testing revealed increases in yield strength and hardness with increasing helium dose from 1000 to 4000 appm He, RMI indicated no significant changes in strength as compared to unimplanted copper. Here, this discrepancy in behavior was rationalized through a combination of recent literature and follow-on molecular dynamics (MD) simulations, leading to the conclusion that the nanoscale helium bubbles acting as dispersed barriers to dislocation motion at quasi-static strain rates collapse under shock loading and cease to be effective barriers at high strain rates.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Integrated simulations of premagnetized and self-magnetizing dynamic screw pinch-driven MagLIF

Magnetically driven implosions such as in magnetized liner inertial fusion (MagLIF) on the Z accelerator suffer from magneto-Rayleigh–Taylor instabilities (MRTI) that dynamically redistribute liner mass during implosion, limiting fusion fuel compression and confinement, which ultimately degrades performance. Driving the implosion with an initially helical drive field that dynamically shifts the direction of the magnetic field surrounding the liner (i.e., a dynamic screw pinch, DSP) is a method proposed to mitigate MRTI in-flight and improve target performance. In DSPs, the axial drive magnetic field component implodes the liner and diffuses through the shocked, melted liner material into the fuel throughout the implosion. Liners can be designed to enable enough axial magnetic flux to diffuse through the liner material to effectively magnetize the fuel region without the need of an initial axial magnetic field (i.e., from external field coils). We present results from three-dimensional radiation-magnetohydrodynamic simulations of MagLIF implosions employing drive magnetic fields composed of axial and azimuthal components (a helical drive field). These simulated DSP-driven MagLIF targets demonstrate improved fuel conditions and thermonuclear yield compared to a traditional MagLIF target implosion. Synthetic x-ray radiography of the imploding liner material and x-ray emission images of the fuel region at the time of peak neutron yield rate indicate superior implosion morphology for DSP-MagLIF implosions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Near-complete extraction of maximum stored energy from large-core fibers using coherent pulse stacking amplification of femtosecond pulses

High field science relies on ultrashort pulse lasers with multi-joule pulse energies for studying light–matter interactions under extreme conditions and for driving particle accelerators and secondary radiation sources of x rays, gamma rays, neutrons, positrons, muons, and protons. Next-generation laser drivers will require a 10 3 -10 4 times increase in pulse repetition rates, producing multi-joule energies at multi-kilowatt average powers to enable practical applications in nuclear engineering, advanced materials, medicine, biology, homeland security, and high-energy physics. Spatially coherently combined femtosecond fiber lasers are recognized as a pathway to these next-generation drivers, with significant practical advantages including high efficiency and the possibility of compact integration. However, chirped pulse amplification in fibers is capable of extracting only a small fraction (usually ~1%) of the maximum stored energy. Here we demonstrate near-complete maximum stored energy extraction with low accumulated nonlinearity from a large-core fiber amplifier using coherent pulse stacking amplification. We have amplified a 81-pulse stacking burst in a 85 µm core chirally coupled core Yb-doped fiber, extracting up to 9.5 mJ (~90% of stored energy) with < 4.5 radians of accumulated nonlinear phase, temporally combined this burst into a single pulse, and achieved 4.2 mJ pulses of 313 fs bandwidth-limited duration after compression. This represents, to our knowledge, the highest energy extracted and compressed into a femtosecond pulse from a single fiber amplifier, enabling approximately two orders of magnitude size reduction of future high-energy coherently spatially combined fiber laser arrays.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

STARFIRE – Science and Technology Accelerated Research for Fusion Innovation and Reactor Engineering progress report

The STARFIRE hub leverages foundational science and technology (S&T) research and integrated plant modeling tools to advance Inertial Fusion Energy (IFE). S&T breakthroughs achieved in each thrust are incorporated into an integrated modeling tool to assess and prioritize remaining gaps to bridge for IFE to become viable. Scientific highlights span high-gain target design, diode-pumped solid-state lasers, and innovative target manufacturing. Key highlights include the investigation of shock propagation through various foam structures among other limiting factors of compression of IFE target, exploration of novel 3D printing techniques such as light-sheet additive manufacturing for 2-photon polymerization foams, and diode-pumped solid-state laser architectures required for several IFE approaches. In addition, the STARFIRE team has established two public-private working groups to address laser diode supply chain issues and test advanced laser diode configurations. Finally, a lite version of the integrated modeling tool has been developed to facilitate outreach and engage with private companies. STARFIRE’s management structure has been designed to ensure agile resource allocation, robust performance assessment, and alignment with the broader fusion energy mission. STARFIRE’s breakthroughs are disseminated to the community via reports, presentations, and publications, while agreements with private companies are set in place to protect proprietary information.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1969

Stress-testing of the throat of a rocket's nozzle

Test motor in which high initial pressure can be reduced suddenly provides a method of testing stress effects in the throat of a rockets nozzle. Motors operating pressure is increased to aggravate tensile stresses in a submerged throat. Opposing compression stresses are limited by control of the operating pressure.

Estes, E. G.↗

NASA NTRS1981

Oxidation-induced contraction and strengthening of boron fibers

An investigation was conducted to measure and understand the physical and mechanical effects that occur in boron fibers during and after thermal treatment in a controlled oxygen argon gaseous mixture. Of principal concern was the optimization of this treatment as a secondary processing method for significantly improving fiber tensile strength. Strengthening was accomplished by an oxidation induced axial contraction of the fiber and a resulting axial compression of strength limiting flaws within the fiber's tungsten boride core. Various physical observations were used to develop mechanistic models for oxidation, contraction, and flow formation. Processing guidelines are discussed for possibly exceeding the 5.5 GN/sq m strength limit and also for achieving fiber strengthening during application of boron containing diffusion barrier coatings.

Dicarlo, J. A.↗

NASA NTRS1985

Relativistic cosmic ray spectra in the full non-linear theory of shock acceleration

The non-linear theory of shock acceleration was generalized to include wave dynamics. In the limit of rapid wave damping, it is found that a finite ave velocity tempers the acceleration of high Mach number shocks and limits the maximum compression ratio even when energy loss is important. For a given spectrum, the efficiency of relativistic particle production is essentially independent of v sub Ph. For the three families shown, the percentage of kinetic energy flux going into relativistic particles is (1) 72%, 2) 44%, and (3) 26% (this includes the energy loss at the upper energy cuttoff). Even small v sub ph, typical of the HISM, produce quasi-universal spectra that depend only weakly on the acoustic Mach number. These spectra should be close enough to e(-2) to satisfy cosmic ray source requirements.

Eichler, D.↗

NASA NTRS1985

Relativistic cosmic-ray spectra in the fully nonlinear theory of shock acceleration

The non-linear theory of shock acceleration was generalized to include wave dynamics. In the limit of rapid wave damping, it is found that a finite wave velocity tempers the acceleration of high Mach number shocks and limits the maximum compression ratio even when energy loss is important. For a given spectrum, the efficiency of relativistic particle production is essentially independent of v sub Ph. For the three families shown, the percentage of kinetic energy flux going into relativistic particles is (1) 72 percent, (2) 44 percent, and (3) 26 percent (this includes the energy loss at the upper energy cutoff). Even small v sub ph, typical of the HISM, produce quasi-universal spectra that depend only weakly on the acoustic Mach number. These spectra should be close enough to e(-2) to satisfy cosmic ray source requirements.

Ellison, D. C.↗