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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metal Additive Manufacturing for Spaceflight

Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.

Additive Manufacturing↗
NASA NTRSDate not supplied

Out-of-plane behavior of selectively stitched curved beams subjected to four-point bending

Through-the-thickness stitching can be used to provide a pathway to reduce interlaminar damage in laminated polymer composites. To decrease the amount of stitching, a selective stitching process is necessary to reduce the total manufacturing time in stitched polymer composites. In this study, L-shaped laminates are stitched in the radius section to arrest out-of-plane damage that can occur when subjected to four-point bending loads. A cohesive zone finite element model of the L-shaped laminate was developed. An embedded spring element approach was used to represent the through-the-thickness reinforcements within the finite element model. Specimens with stitches in the radius region of the L-shaped laminate were found to have greater maximum loads before failure. The through-the-thickness stitches are observed to locally reduce the radial stresses in the radius region of the L-shaped laminate, which results in delamination growth away from the radius centerline and greater load-carrying capability.

Stitched Composites↗
DOE OSTI2020

Overcoming Real Project Challenges

Four case studies are presented at a high level about how project challenges were successfully addressed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

System and method for large-scale PCB production including continuous selective adhesion

A method for the large-scale production of PCBs including a continuous selective adhesion process for creating printed circuit traces providing input to a production line. A roll of printed circuit traces is produced using rolls of flexible substrate, conductive layer, and conductive layer support by applying adhesive between the rolls of flexible substrate and conductive layer, bringing the rolls together, transferring a circuit pattern onto the flexible substrate, curing the adhesive through non-opaque areas of the circuit pattern, and separating the non-bonded areas. The resulting printed circuit traces are applied from the roll to mounts, and circuit components are applied from a roll to the traces as the mounts move along the line. Additional rolls of printed circuit traces and circuit components may be incorporated, and multi-layer PCBs may be produced. As part of the production line, the finished PCBs may be applied to flat or contoured products.

Hatch, Jonathan Douglas↗
DOE OSTI2022

Fusion 2021 Best Paper Awards

The 24th International Conference on Information Fusion (FUSION 2021) was held in hybrid mode (virtual and in person) during November 1-4, 2021. FUSION is the flagship event of the International Society of Information Fusion (ISIF), and the conference is well established as the premiere forum to present and discuss research progress and initiatives in the information fusion areas. This article described the process and selection of best papers awards under general and student categories.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Nitinol Electroslag Remelting: Initial Slag Study

Nitinol’s unique shape memory and super-elastic properties make it attractive for many applications in biomedical, automotive, aerospace, industrial refrigeration, and waste heat reclamation industries. The fatigue performance is limited however, by non-metallic inclusions (NMI) formed during the traditional VIM/VAR or multi-VAR process. ESR is a potential alternative melt process and is commonly used to refine ingot chemistry and enhance the metallurgical structure of many superalloys and specialty steels, but no study on ESR of Nitinol has been reported to date. The key to establishing a successful ESR process is selecting a compatible slag. In this study, several different slag chemistries are evaluated for their compatibility with Nitinol. One slag chemistry is chosen, along with a control, to produce four Nitinol ESR ingots. Pursuit of a novel slag chemistry for adequate Nitinol refinement is discussed.

Fezi, Kyle↗
DOE OSTI2022

Bio-Optimized Technologies to Keep Thermoplastics out of Landfills and the Environment (BOTTLE)

Plastics have revolutionized modern life, but reliance on these fossil-based materials that persist for centuries is causing a pollution crisis and contributing to greenhouse gas (GHG) emissions. To develop new technologies to address this problem, the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium will deliver selective, scalable technologies to enable cost-effective recycling, upcycling, and increased energy efficiency. BOTTLE is an interdisciplinary team of experts that aim to develop selective, scalable processes to deconstruct and upcycle today's plastics and thermosets, redesign tomorrow's plastics to be recyclable-by-design (RBD) and derived from both bio-based and plastic waste-based feedstocks, work with industrial partners across the value chain to catalyze the circular economy for plastics, and leverage AMO and BETO investments in analysis-guided R&D, integrated process development, chemical and biological catalysis, materials characterization, modeling, and data science. BOTTLE is guided by techno-economic analysis (TEA) and supply chain-based life-cycle assessment (LCA). BOTTLE comprises members from ten partner institutions. Primary outcomes to date include establishment of a full consortium, impactful, benchmarking analyses that will be important for the plastics recycling and upcycling community, and multiple impactful, high-impact publications across the breadth of our research portfolio.

bio-optimized↗
DOE OSTI2025

A Joint Search for the Electromagnetic Counterpart to the Gravitational-Wave Binary Black-Hole Merger Candidate S250328ae with the Dark Energy Camera and the Prime Focus Spectrograph

The first detection of an optical counterpart to a gravitational wave signal revealed that collaborative efforts between instruments with different specializations provide a unique opportunity to acquire impactful multi-messenger data. We present results of such a joint search with the Dark Energy Camera (DECam) and Prime Focus Spectrograph (PFS) for the optical counterpart of the LIGO-Virgo-KAGRA event S250328ae, a binary black hole merger candidate of high significance detected at a distance of 511$\pm$82 Mpc and localized within an area of 3 (15) square degrees at 50% (90%) confidence. We observed the 90% confidence area with DECam and identified 36 high-confidence transient candidates after image processing, candidate selection, and candidate vetting. We observed with PFS to obtain optical spectra of DECam candidates, Swift-XRT candidates, and potential host galaxies of S250328ae. In total, 3897 targets were observed by seven pointings covering ~50% of the 90% confidence area. After template fitting and visual inspection, we identified 12 SNe, 159 QSOs, 2975 galaxies, and 131 stars. With the joint observations of DECam and PFS, we found variability in 12 SNe, 139 QSOs, 37 galaxies, and 2 stars. We do not identify any confident optical counterparts, though the association is not ruled out for three variable candidates that are not observed by PFS and 6 QSO candidates without clear variability if the optical counterpart of S250328ae is faint. Despite the lack of confident optical counterparts, this paper serves as a framework for future collaborations between wide-field imagers and multi-object spectrographs to maximize multi-messenger analyses.

Zhang, Haibin [Natl. Astron. Observ. of Japan] (OR↗
NASA NTRS2002

Stimulus-response compatibility and psychological refractory period effects: implications for response selection

The purpose of this paper was to provide insight into the nature of response selection by reviewing the literature on stimulus-response compatibility (SRC) effects and the psychological refractory period (PRP) effect individually and jointly. The empirical findings and theoretical explanations of SRC effects that have been studied within a single-task context suggest that there are two response-selection routes-automatic activation and intentional translation. In contrast, all major PRP models reviewed in this paper have treated response selection as a single processing stage. In particular, the response-selection bottleneck (RSB) model assumes that the processing of Task 1 and Task 2 comprises two separate streams and that the PRP effect is due to a bottleneck located at response selection. Yet, considerable evidence from studies of SRC in the PRP paradigm shows that the processing of the two tasks is more interactive than is suggested by the RSB model and by most other models of the PRP effect. The major implication drawn from the studies of SRC effects in the PRP context is that response activation is a distinct process from final response selection. Response activation is based on both long-term and short-term task-defined S-R associations and occurs automatically and in parallel for the two tasks. The final response selection is an intentional act required even for highly compatible and practiced tasks and is restricted to processing one task at a time. Investigations of SRC effects and response-selection variables in dual-task contexts should be conducted more systematically because they provide significant insight into the nature of response-selection mechanisms.

Review Literature↗
NASA NTRS2014

Electrostatic Levitation for Studies of Additive Manufactured Materials

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL in supporting the development and modeling of the selective laser melting process for metals, and provide an overview of the results to date.

SanSoucie, Michael P.↗
DOE OSTI2022

Microbiome breeding: conceptual and practical issues

Microbiome breeding is a new artificial selection technique that seeks to change the genetic composition of microbiomes in order to benefit plant or animal hosts. Recent experimental and theoretical analyses have shown that microbiome breeding is possible whenever microbiome-encoded genetic factors affect host traits (e.g., health) and microbiomes are transmissible between hosts with sufficient fidelity, such as during natural microbiome transmission between individuals of social animals, or during experimental microbiome transplanting between plants. Further, to address misunderstandings that stymie microbiome-breeding programs, we (i) clarify and visualize the corresponding elements of microbiome selection and standard selection; (ii) elucidate the eco-evolutionary processes underlying microbiome selection within a quantitative genetic framework to summarize practical guidelines that optimize microbiome breeding; and (iii) characterize the kinds of host species most amenable to microbiome breeding.

60 APPLIED LIFE SCIENCES↗
NASA NTRS1975

Study of materials for space processing

Materials were selected for device applications and their commercial use. Experimental arrangements were also made for electrical characterization of single crystals using electrical resistivity and Hall effect measurements. The experimental set-up was tested with some standard samples.

Lal, R. B.↗
NASA NTRS1986

Silicon material task review

The objectives of the Flat-plate Solar Array (FSA) Project Silicon Material Task are to evaluate technologies, new and old; to develop the most promising technologies; to establish practicality of the processes to meet production, energy use, and economic criteria; and to develop an information base on impurities in polysilicon and to determine their effects on solar cell performance. The approach involves determining process feasibility, setting milestones for the forced selection of the processes, and establishing the technical readiness of the integrated process.

Lorenz, J. H.↗
NASA NTRS1993

Hand controller commonality evaluation process

Hand controller selection for NASA's Orbiter and Space Station Freedom is an important area of human-telerobot interface design and evaluation. These input devices will control remotely operated systems that include large crane-like manipulators (e.g., Remote Manipulator System or RMS), smaller, more dexterous manipulators (e.g., Flight Telerobotic Servicer or FTS), and free flyers (e.g., Orbital Maneuvering Vehicle or OMV). Candidate hand controller configurations for these systems vary in many ways: shape, size, number of degrees-of-freedom (DOF), operating modes, provision of force reflection, range of movement, and 'naturalness' of use. Unresolved design implementation issues remain, including such topics as how the current Orbiter RMS rotational and translational rate hand controllers compare with the proposed Space Station Freedom hand controllers, the advantages that position hand controllers offer for these applications, and whether separate hand controller configurations are required for each application. Since previous studies contain little empirical hand controller task performance data, a controlled study is needed that tests Space Station Freedom candidate hand controllers during representative tasks. This study also needs to include anthropometric and biomechanical considerations.

Stuart, Mark A.↗