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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

National Launch System: Structures and materials

The National Launch System provides an opportunity to realize the potential of Al-Li. Advanced structures can reduce weights by 5-40 percent as well as relax propulsion system performance specifications and reduce requirements for labor and materials. The effect on costs will be substantial. Advanced assembly and process control technologies also offer the potential for greatly reduced labor during the manufacturing and inspection processes. Current practices are very labor-intensive and, as a result, labor costs far outweigh material costs for operational space transportation systems. The technological readiness of new structural materials depends on their commercial availability, producibility and materials properties. Martin Marietta is vigorously pursuing the development of its Weldalite 049 Al-Li alloys in each of these areas. Martin Marietta is also preparing to test an automated work cell concept that it has developed using discrete event simulation.

Bunting, Jack O.↗
NASA NTRSDate not supplied

On the Use of Resilience Models as Digital Twins for Operational Support and In time Decision Making

Human error is a major contributor to accidents and performance losses in complex engineered systems. If one examines these human error caused failures further, a specific cause, the lack of situation awareness, has dominated as a major cause of human errors that instigate latent or catastrophic failures in complex systems. Studies of aviation accidents involving major air carriers revealed that situation awareness was the root cause of around 90% of accidents involving pilot error. Another study explored offshore drilling accidents involving human error and found that 40% of accidents were directly attributed to the loss of situation awareness. Studies of human errors in other domains such as nuclear power, air traffic control, process industry, and advanced driving show that loss of SA was a root cause in a majority of the events. Situation awareness-related failures are not only common but also costly and fatal (e.g., Bhopal Gas Leak, Air France 447 Flight Crash). Thus, the concept of situation awareness has emerged as an important construct in human factors, resulting in numerous models and measurement methods to aid in promoting appropriate levels of situation awareness.

Lukman Irshad↗
NASA NTRS1991

Advanced optical sensing and processing technologies for the distributed control of large flexible spacecraft

The objective was to examine state-of-the-art optical sensing and processing technology applied to control the motion of flexible spacecraft. Proposed large flexible space systems, such an optical telescopes and antennas, will require control over vast surfaces. Most likely distributed control will be necessary involving many sensors to accurately measure the surface. A similarly large number of actuators must act upon the system. The used technical approach included reviewing proposed NASA missions to assess system needs and requirements. A candidate mission was chosen as a baseline study spacecraft for comparison of conventional and optical control components. Control system requirements of the baseline system were used for designing both a control system containing current off-the-shelf components and a system utilizing electro-optical devices for sensing and processing. State-of-the-art surveys of conventional sensor, actuator, and processor technologies were performed. A technology development plan is presented that presents a logical, effective way to develop and integrate advancing technologies.

Williams, G. M.↗
DOE OSTI2023

Directed Energy Deposition Process Modeling, Validation, and Process-Informed Optimization

The directed energy deposition (DED) process, one of the most popular additive manufacturing techniques in use today, involves various complex physical mechanisms that are not yet well understood. In this regard, computational tools show promise for elucidating the manufacturing process and enabling nondestructive performance evaluations of manufactured parts. To better control and optimize the DED process?thereby improving the manufactured product? the present work develops and demonstrates a novel artificial intelligence (AI)-based process control and optimization technique. Specifically, a geometry-free thermo-mechanical model with adaptive subdomain construction is developed to accurately capture the material?s thermo-mechanical response under cyclical reheating and high cooling rates [1]. The model is demonstrated and validated with experimental measurements, in light of various geometries and processing parameters. Moreover, based on this thermo-mechanical model, a physics-informed reduced-order model is developed to enable quick predictions of the temperature field at every time step. Furthermore, an AI-based controller is developed that can adapt to the ever-changing system states by automatically adjusting the manufacturing process parameters. This entire work is based on the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) [2] and its recent integration with Libtorch (the C++ frontend of PyTorch [3]). The combined development of the adaptive material deposition scheme, thermo-mechanical model, associated reduced-order model, and AI-based process controller carries great potential for improving advanced manufacturing processes.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Flexible control techniques for a lunar base

The fundamental elements found in every terrestrial control system can be employed in all lunar applications. These elements include sensors which measure physical properties, controllers which acquire sensor data and calculate a control response, and actuators which apply the control output to the process. The unique characteristics of the lunar environment will certainly require the development of new control system technology. However, weightlessness, harsh atmospheric conditions, temperature extremes, and radiation hazards will most significantly impact the design of sensors and actuators. The controller and associated control algorithms, which are the most complex element of any control system, can be derived in their entirety from existing technology. Lunar process control applications -- ranging from small-scale research projects to full-scale processing plants -- will benefit greatly from the controller advances being developed today. In particular, new software technology aimed at commercial process monitoring and control applications will almost completely eliminate the need for custom programs and the lengthy development and testing cycle they require. The applicability of existing industrial software to lunar applications has other significant advantages in addition to cost and quality. This software is designed to run on standard hardware platforms and takes advantage of existing LAN and telecommunications technology. Further, in order to exploit the existing commercial market, the software is being designed to be implemented by users of all skill levels -- typically users who are familiar with their process, but not necessarily with software or control theory. This means that specialized technical support personnel will not need to be on-hand, and the associated costs are eliminated. Finally, the latest industrial software designed for the commercial market is extremely flexible, in order to fit the requirements of many types of processing applications with little or no customization. This means that lunar process control projects will not be delayed by unforeseen problems or last minute process modifications. The software will include all of the tools needed to adapt to virtually any changes. In contrast to other space programs which required the development of tremendous amounts of custom software, lunar-based processing facilities will benefit from the use of existing software technology which is being proven in commercial applications on Earth.

Kraus, Thomas W.↗
DOE OSTI2019

Embedment of sensors in ceramic structures

Ceramic materials such as silicon carbide (SiC) are attractive for many nuclear applications due to their ability to withstand high temperatures, which inherently improve the thermal efficiency of the power conversion cycle and can in some cases provide high-temperature process heat. SiC is particularly attractive because of its high-temperature strength retention, stability under neutron irradiation, and low neutron absorption. The TCR program has recently demonstrated the ability to fabricate monolithic SiC components with complex geometries using a binder jet additive manufacturing technique followed by densification using chemical vapor infiltration (CVI). This technology presents an opportunity to embed sensors within ceramic components at critical locations that allow for enhanced process monitoring and control of advanced nuclear energy systems. The challenges with embedding sensors in ceramic components are to identify appropriate materials that can survive the CVI process, remain embedded after cooling to room temperature, and be suitable for operation in a high-temperature nuclear environment. This report summarizes the sensors that are being considered for embedding within ceramics, the sensor embedding process, material compatibility studies, and characterization of the embedded components. Material selection is first guided by computational thermodynamics and is confirmed by embedding coupons and examining material interactions using electron microscopy. This work shows that a wide range of refractory metals, as well as certain fiber optic sensors, can be successfully embedded in 3D-printed SiC. Future work will involve testing of functional sensors including thermocouples and optical fiber-based, spatially distributed temperature/strain sensors.

36 MATERIALS SCIENCE↗
NASA NTRS2000

Accelerating Innovation: Turning Goals into Reality

The success of NASA's programs depends upon innovation, which is recognized by several characteristics. All aspects of a program including tools, processes, materials, subsystems, vehicles, and operations should be evaluated to determine possible innovations which might be implemented. Several examples are presented of ways in which innovation has substantially furthered the goals of NASA. The specific fields mentioned include high performance computing, advanced technologies for aerospace system design, advanced materials and manufacturing processes, neural based flight control, linear aerospike engines, advanced space propulsion systems, high altitude and long duration autonomous flights, advanced vehicle concepts, advanced space propulsion systems, as well as advanced weather information. A final list details the perceived ways in which NASA can benefit from continued innovation in such ways as partnering with the private sector.

VanDalsem, William R.↗
DOE OSTI2015

Advanced High-Level Waste Glass Research and Development Plan

The U.S. Department of Energy Office of River Protection (ORP) has implemented an integrated program to increase the loading of Hanford tank wastes in glass while meeting melter lifetime expectancies and process, regulatory, and product quality requirements. The integrated ORP program is focused on providing a technical, science-based foundation from which key decisions can be made regarding the successful operation of the Hanford Tank Waste Treatment and Immobilization Plant (WTP) facilities. The fundamental data stemming from this program will support development of advanced glass formulations, key process control models, and tactical processing strategies to ensure safe and successful operations for both the low-activity waste (LAW) and high-level waste (HLW) vitrification facilities with an appreciation toward reducing overall mission life. The purpose of this advanced HLW glass research and development plan is to identify the near-, mid-, and longer-term research and development activities required to develop and validate advanced HLW glasses and their associated models to support facility operations at WTP, including both direct feed and full pretreatment flowsheets. This plan also integrates technical support of facility operations and waste qualification activities to show the interdependence of these activities with the advanced waste glass (AWG) program to support the full WTP mission. Figure ES-1 shows these key ORP programmatic activities and their interfaces with both WTP facility operations and qualification needs. The plan is a living document that will be updated to reflect key advancements and mission strategy changes. The research outlined here is motivated by the potential for substantial economic benefits (e.g., significant increases in waste throughput and reductions in glass volumes) that will be realized when advancements in glass formulation continue and models supporting facility operations are implemented. Developing and applying advanced glass formulations will reduce the cost of Hanford tank waste management by reducing the schedule for tank waste treatment and reducing the amount of HLW glass for storage, transportation, and disposal. Additional benefits will be realized if advanced glasses are developed that demonstrate more tolerance for key components in the waste (such as Al 2 O 3 , Cr 2 O 3 , SO 3 and Na 2 O) above the currently defined WTP constraints. Tolerating these higher concentrations of key waste loading limiters may reduce the burden on (or even eliminate the need for) leaching to remove Cr and Al and washing to remove excess S and Na from the HLW fraction. Advanced glass formulations may also make direct vitrification of the HLW fraction without significant pretreatment more cost effective. Finally, the advanced glass formulation efforts seek not only to increase waste loading in glass, but also to increase glass production rate. When coupled with higher waste loading, ensuring that all of the advanced glass formulations are processable at or above the current contract processing rate leads to significant improvements in waste throughput (the amount of waste being processed per unit time),which could significantly reduce the overall WTP mission life. The integration of increased waste loading, reduced leaching/washing requirements, and improved melting rates provides a system-wide approach to improve the effectiveness of the WTP process.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2014

Improved Broadband Liner Optimization Applied to the Advanced Noise Control Fan

The broadband component of fan noise has grown in relevance with the utilization of increased bypass ratio and advanced fan designs. Thus, while the attenuation of fan tones remains paramount, the ability to simultaneously reduce broadband fan noise levels has become more desirable. This paper describes improvements to a previously established broadband acoustic liner optimization process using the Advanced Noise Control Fan rig as a demonstrator. Specifically, in-duct attenuation predictions with a statistical source model are used to obtain optimum impedance spectra over the conditions of interest. The predicted optimum impedance information is then used with acoustic liner modeling tools to design liners aimed at producing impedance spectra that most closely match the predicted optimum values. Design selection is based on an acceptance criterion that provides the ability to apply increased weighting to specific frequencies and/or operating conditions. Constant-depth, double-degree of freedom and variable-depth, multi-degree of freedom designs are carried through design, fabrication, and testing to validate the efficacy of the design process. Results illustrate the value of the design process in concurrently evaluating the relative costs/benefits of these liner designs. This study also provides an application for demonstrating the integrated use of duct acoustic propagation/radiation and liner modeling tools in the design and evaluation of novel broadband liner concepts for complex engine configurations.

Nark, Douglas M.↗
NASA NTRS2015

Modeling of Broadband Liners Applied to the Advanced Noise Control Fan

The broadband component of fan noise has grown in relevance with an increase in bypass ratio and incorporation of advanced fan designs. Therefore, while the attenuation of fan tones remains a major factor in engine nacelle acoustic liner design, the simultaneous reduction of broadband fan noise levels has received increased interest. As such, a previous investigation focused on improvements to an established broadband acoustic liner optimization process using the Advanced Noise Control Fan (ANCF) rig as a demonstrator. Constant-depth, double-degree of freedom and variable-depth, multi-degree of freedom liner designs were carried through design, fabrication, and testing. This paper addresses a number of areas for further research identified in the initial assessment of the ANCF study. Specifically, incident source specification and uncertainty in some aspects of the predicted liner impedances are addressed. This information is incorporated in updated predictions of the liner performance and comparisons with measurement are greatly improved. Results illustrate the value of the design process in concurrently evaluating the relative costs/benefits of various liner designs. This study also provides further confidence in the integrated use of duct acoustic propagation/radiation and liner modeling tools in the design and evaluation of novel broadband liner concepts for complex engine configurations.

Nark, Douglas M.↗
DOE OSTI2026

Recent progress in atomic-scale controlled plasma processing

Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.

Ishikawa, Kenji [Nagoya Univ. (Japan)] (ORCID:0000↗
DOE OSTI2026

Enabling integrated AI control on DIII-D: a control system design with state-of-the-art experiments

We present the design and application of a general algorithm for Prediction And Control using MAchiNe learning (PACMAN) in DIII-D. Machine learning (ML)-based predictors and controllers have shown great promise in achieving regimes in which traditional controllers fail, such as tearing mode (TM) free scenarios, ELM-free scenarios and stable advanced tokamak conditions. The architecture presented here was deployed on DIII-D to facilitate the end-to-end implementation of advanced control experiments, from diagnostic processing to final actuation commands. This paper describes the detailed design of the algorithm and explains the motivation behind each design point. We also describe several successful ML control experiments in DIII-D using this algorithm, including a reinforcement learning controller targeting advanced non-inductive plasmas, a wide-pedestal quiescent H-mode ELM predictor, an Alfvén Eigenmode controller, a Model Predictive Control plasma profile controller and a state-machine TM predictor-controller. There is also discussion on guiding principles for real-time ML controller design and implementation.

machine learning↗
NASA NTRS1990

Operational efficiency subpanel advanced mission control

Herein, the term mission control will be taken quite broadly to include both ground and space based operations as well as the information infrastructure necessary to support such operations. Three major technology areas related to advanced mission control are examined: (1) Intelligent Assistance for Ground-Based Mission Controllers and Space-Based Crews; (2) Autonomous Onboard Monitoring, Control and Fault Detection Isolation and Reconfiguration; and (3) Dynamic Corporate Memory Acquired, Maintained, and Utilized During the Entire Vehicle Life Cycle. The current state of the art space operations are surveyed both within NASA and externally for each of the three technology areas and major objectives are discussed from a user point of view for technology development. Ongoing NASA and other governmental programs are described. An analysis of major research issues and current holes in the program are provided. Several recommendations are presented for enhancing the technology development and insertion process to create advanced mission control environments.

Friedland, Peter↗
NASA NTRS1997

Smart-Pixel Array Processors Based on Optimal Cellular Neural Networks for Space Sensor Applications

A smart-pixel cellular neural network (CNN) with hardware annealing capability, digitally programmable synaptic weights, and multisensor parallel interface has been under development for advanced space sensor applications. The smart-pixel CNN architecture is a programmable multi-dimensional array of optoelectronic neurons which are locally connected with their local neurons and associated active-pixel sensors. Integration of the neuroprocessor in each processor node of a scalable multiprocessor system offers orders-of-magnitude computing performance enhancements for on-board real-time intelligent multisensor processing and control tasks of advanced small satellites. The smart-pixel CNN operation theory, architecture, design and implementation, and system applications are investigated in detail. The VLSI (Very Large Scale Integration) implementation feasibility was illustrated by a prototype smart-pixel 5x5 neuroprocessor array chip of active dimensions 1380 micron x 746 micron in a 2-micron CMOS technology.

Fang, Wai-Chi↗
DOE OSTI2024

NREL Hydrogen Sensor Testing Laboratory

Relevance: Detection is recognized as a critical element for hydrogen facility safety design and supports risk mitigation. Detection methodologies will support validation of H2 behavior research. Hydrogen point sensors play a critical role for safety and process monitoring, but other methodologies can be developed. Approach: NREL Sensor Laboratory tests and verifies sensor performance for manufacturers, developers, end-users, regulatory agencies and SDOs/CDOs NREL deployment activity supports regulatory requirement verification, hydrogen behavior models, and method development for use by stakeholders. Accomplishments and Progress: NREL's R&D accomplishments have supported developers, industry, and SDOs by providing sensor performance and deployment expertise not otherwise available. Development of alternative detection strategies for hydrogen applications have been initiated. HyWAM and advanced detection methodologies deployments at H2@Scale Facilities are being implemented. Collaborations: Collaboration with government laboratories, universities, private organizations and regulatory agencies has leveraged the NREL Sensor Laboratory's success in advancing hydrogen safety sensors and process control. Proposed Future Work: NREL will support hydrogen deployment by the proper implementation of hydrogen sensors and advanced detection strategies. NREL will continue to support science-based codes and standards. This effort will be guided by the needs of the hydrogen community.

codes and standards↗
DOE OSTI2020

Computational modeling and neutron imaging to understand interface shape and solute segregation during the vertical gradient freeze growth of BaBrCl:Eu

In this work we apply continuum models to analyze phase change, heat transfer, fluid flow, solute transport, and segregation in order to understand prior neutron imaging observations of the vertical gradient freeze growth of Eu-doped BaBrCl. The models provide a rigorous framework in which to understand the mechanisms that are responsible for the complicated evolution of interface shape and dopant distribution in the growth experiment. We explain how a transition in the solid/liquid interface shape from concave to convex is driven by changes in radial heat transfer caused by furnace design. We also provide a mechanistic explanation of how dynamic growth conditions and changes of the flow structure in the melt result in complicated segregation patterns in this system. A growth pause caused by controller lock-up is shown to result in a band of solute depletion in accordance with classical theory. However, changing flow patterns during growth result in a non-monotonic axial distribution of solute that cannot be explained by simple application of classical segregation models. We assert that the approach presented here, namely the use of rigorous models in conjunction advanced diagnostics, such as neutron imaging, provides an exciting path forward for process optimization and control, accelerating the incremental advances that have, in the past, typically relied on empiricism, experience, and intuition.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Quantum cascade laser based monitoring of CF{sub 2} radical concentration as a diagnostic tool of dielectric etching plasma processes

Dielectric etching plasma processes for modern interlevel dielectrics become more and more complex by the introduction of new ultra low-k dielectrics. One challenge is the minimization of sidewall damage, while etching ultra low-k porous SiCOH by fluorocarbon plasmas. The optimization of this process requires a deeper understanding of the concentration of the CF{sub 2} radical, which acts as precursor in the polymerization of the etch sample surfaces. In an industrial dielectric etching plasma reactor, the CF{sub 2} radical was measured in situ using a continuous wave quantum cascade laser (cw-QCL) around 1106.2 cm{sup −1}. We measured Doppler-resolved ro-vibrational absorption lines and determined absolute densities using transitions in the ν{sub 3} fundamental band of CF{sub 2} with the aid of an improved simulation of the line strengths. We found that the CF{sub 2} radical concentration during the etching plasma process directly correlates to the layer structure of the etched wafer. Hence, this correlation can serve as a diagnostic tool of dielectric etching plasma processes. Applying QCL based absorption spectroscopy opens up the way for advanced process monitoring and etching controlling in semiconductor manufacturing.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗