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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Optimal design of solidification processes

An optimal design algorithm is presented for the analysis of general solidification processes, and is demonstrated for the growth of GaAs crystals in a Bridgman furnace. The system is optimal in the sense that the prespecified temperature distribution in the solidifying materials is obtained to maximize product quality. The optimization uses traditional numerical programming techniques which require the evaluation of cost and constraint functions and their sensitivities. The finite element method is incorporated to analyze the crystal solidification problem, evaluate the cost and constraint functions, and compute the sensitivities. These techniques are demonstrated in the crystal growth application by determining an optimal furnace wall temperature distribution to obtain the desired temperature profile in the crystal, and hence to maximize the crystal's quality. Several numerical optimization algorithms are studied to determine the proper convergence criteria, effective 1-D search strategies, appropriate forms of the cost and constraint functions, etc. In particular, we incorporate the conjugate gradient and quasi-Newton methods for unconstrained problems. The efficiency and effectiveness of each algorithm is presented in the example problem.

Dantzig, Jonathan A.↗
NASA NTRSDate not supplied

Design for Manufacturing of Structures with Automated Fiber Placement via Integration of Analysis and Process Planning

Under the Design for Manufacturing (DFM) task in the NASA HiCAM program, significant process has been made towards establishing a fully automated optimization process that spans the structural analysis, design, and manufacturing process planning for Automated Fiber Placement (AFP) structures. Previous efforts in this area established the data formats and mapping processes needed to exchange data between disciplines. The software tools used in the framework are HyperX (structural optimization), CAPP (process planning), and VCP (AFP path generation). The work has culminated with automation of data exchanges and an optimization process that drives the three software toward convergence. Within this framework, HyperX is used to generate mass-optimum composite designs which are iterated with VCP and CAPP to improve manufacturability of the designs. As the ply manufacturing process is adjusted by CAPP and VCP, HyperX continually re-assesses the structural integrity of the part and makes adjustments to the laminate as needed. For example, the position of fiber steering and tow overlaps/gaps can necessitate changes to the laminate design. Once the design converges, the end result is a stack of plies that meets both structural and manufacturing requirements. This paper presents the details of the framework and demonstrations the automated process on several parts with significant double-curvature.

HiCAM↗
NASA NTRS1991

General shape optimization capability

A method is described for calculating shape sensitivities, within MSC/NASTRAN, in a simple manner without resort to external programs. The method uses natural design variables to define the shape changes in a given structure. Once the shape sensitivities are obtained, the shape optimization process is carried out in a manner similar to property optimization processes. The capability of this method is illustrated by two examples: the shape optimization of a cantilever beam with holes, loaded by a point load at the free end (with the shape of the holes and the thickness of the beam selected as the design variables), and the shape optimization of a connecting rod subjected to several different loading and boundary conditions.

Chargin, Mladen K.↗
NASA NTRS1990

Shape optimization for maximum stability and dynamic stiffness

Any optimization of structures for maximum stability or for maximum dynamic stiffness deals with an eigenvalue problem. The goal of this optimization is to raise the lowest eigenvalue (or eigenvalues) of the problem to its highest (optimal) level at a constant volume of the structure. Likely the lowest eigenvalue may be either inherently multi-modal or it can become multi-modal as a result of the optimization process. The multimodeness introduces some ambiguity to the eigenvalue problem and make the optimization difficult to handle. Thus far, only the simplest cases of multi-modal structures have been effectively optimized using rather elaborate analytical methods. Numerous publications report design of a minimum volume structure with different eigenvalues constraints, in which, however, the modality of the problem is assumed a priori. The method presented here utilizes a multi-modal optimality criteria and allows for inclusion of an arbitrary number of buckling or vibrations modes which might influence the optimization process. The real multi-modality of the problem, that is the number of modes participating in the final optimal design is determined iteratively. Because of a natural use of the FEM technique the method is easy to program and might be helpful in design of large flexible space structures.

Szyszkowski, W.↗
DOE OSTI2025

PrOMMiS Tutorial

This is a tutorial on using parameter estimation and process optimization in PrOMMiS. The tutorials are publicly available in the GitHub repository. The presentation attached guides through the flow of the three different tutorials. The tutorials are presented as follows: i) Parameter estimation of oxalate precipitation, ii) Optimization of precipitation model, and iii) Optimization of full process.

critical minerals and materials↗
DOE OSTI2025

High-Power Impulse Magnetron Sputter Deposition of Boron Carbide with Full-Face Erosion Magnetron and Mixed Ar-Ne Plasma

Boron carbide (B 4 C) is an attractive inertial confinement fusion ablator material. The fabrication of B4C ablators by magnetron sputtering requires process optimization. To increase process flexibility, here we explore high-power impulse magnetron sputter (HiPIMS) deposition of B 4 C in pure Ar and mixed Ar-Ne plasmas. Here, the results show that higher plasma discharge currents can be reached with a mixed Ar-Ne plasma in the entire working pressure range studied (5 𝑡𝑜 50 mTorr). At 45 mTorr with 10% of Ne in the Ar-Ne mix, high peak target current densities of ~1 A cm −2 were demonstrated. Films deposited with such a mixed Ar-Ne plasma with a full-face erosion magnetron source on substrates biased at −25 V exhibited higher density and improved mechanical properties, albeit with higher compressive residual stresses compared to the case of HiPIMS deposition in a pure Ar plasma. This work demonstrates additional process flexibility of the HiPIMS discharge mode for the deposition of B 4 C coatings.

Ablator capsule↗
NASA NTRS1984

Evaluation of LANDSAT-4 Thematic Mapper Data as Applied to Geologic Exploration: Summary of Results

As with any tool applied to geologic exploration, maximum value results from the innovative integration of optimally processed LANDSAT-4 data with existing pertinent information and perceptive geologic thinking. The synoptic view of the satellite images and the relatively high resolution of the data permits recognization of regional tectonic patterns and their detailed mapping. The refined spatial and spectral characteristics and digital nature surface alterations associated with hydrothermal activity and microseepage of hydrocarbons. In general, as vegetation and soil cover increase, the value of spectral components of TM data decreases with respect to the value of the spatial component of the data. This observation reinforces the experience from working with MSS data that digital processing must be optimized both for the area and for the application.

Dykstra, J. D.↗
DOE OSTI2025

Process-Microstructure-Property Relationships in Low Heat Input Wire-Arc Additive Manufacturing (WAAM) of Ni-Based Superalloy Haynes 282

Conference presentation on WAAM process optimization on Ni-based superalloy Haynes® 282®. This alloy is targeted for advanced power generation systems for its superior high temperature mechanical properties. Wire-arc additive manufacturing (WAAM) offers attractive cost and materials savings with high deposition rates. Based on initial build process optimization, WAAM blocks were made, and screened for defects using high-throughput CT scanning. The microstructural evolution in arc energy range of 250-700 J/mm was characterized in the as-built and aged conditions, using electron microscopy. Results showed self-consistent microstructure across conditions, with grain size dependence on arc energy, MC and M6C carbides in as-built, and blocky grain boundary M23C6 in as-heat-treated condition. Further reductions in as-built porosity were explored through 20+ combinations of H2 and CO2 additions to shielding gas. Initial results show improved wetting behavior, and bead overlap with up to 1% H2 and up to 0.25% CO2. Combination of experimentally determined datasets provided comprehensive understanding of process-structure-property relationships in WAAM Haynes 282.

Haynes 282↗
NASA NTRS1993

An investigation of squeeze-cast alloy 718

Alloy 718 billets produced by the squeeze-cast process have been evaluated for use as potential replacements for propulsion engine components which are normally produced from forgings. Alloy 718 billets were produced using various processing conditions. Structural characterizations were performed on 'as-cast' billets. As-cast billets were then homogenized and solution treated and aged according to conventional heat-treatment practices for this alloy. Mechanical property evaluations were performed on heat-treated billets. As-cast macrostructures and microstructures varied with squeeze-cast processing parameters. Mechanical properties varied with squeeze-cast processing parameters and heat treatments. One billet exhibited a defect free, refined microstructure, with mechanical properties approaching those of wrought alloy 718 bar, confirming the feasibility of squeeze-casting alloy 718. However, further process optimization is required, and further structural and mechanical property improvements are expected with process optimization.

Gamwell, W. R.↗
DOE OSTI2025

Performance Evaluation of LPBF Manufactured 316H Components

This work represents the continuation of a benchmark study that includes modeling, fabrication and characterization as demonstration to support industry’s adoption of advanced manufacturing processes in a variety of structures. This comprehensive study investigated the feasibility of using additive manufacturing (AM) technologies, specifically Laser Powder Direct Energy Deposition (LP-DED) and Laser Powder Bed Fusion (LPBF), to produce complex nuclear microreactor components using 316H stainless steel. The research focused on manufacturing an expanded elbow pipe component with transitioning sections, which are traditionally difficult and costly to produce through conventional manufacturing methods. The overall study’s primary objectives are therefore demonstrating AM viability for nuclear applications, optimizing process parameters, developing comprehensive material characterization protocols, validating computational modeling approaches, and establishing manufacturing guidelines for complex geometries. Although the initial work included the phased approach of cubical, upscaled cylindrical components, it is to enable to obtain more knowledge for the printing of the expanded elbow structure. The project achieved significant progress in process development by successfully optimizing LP-DED parameters to achieve 99.16-99.97% relative density in 316H stainless steel components. Through systematic evaluation of sixteen cube samples with varied laser powers (400-700W) and scan speeds (600-900 mm/min), optimal processing windows were identified at 500-550W with 600-700 mm/min or 650-700W with 650-900 mm/min scan speeds. The DED manufactured 316H demonstrated mechanical properties comparable or superior to wrought materials, with Young's modulus ranging from 153-208 GPa and controlled microstructural characteristics including greater than 95% face-centered cubic (FCC) phases and engineered cellular structures with sizes between 3.23-6.17 µm.

36 MATERIALS SCIENCE↗
NASA NTRS1998

Design Process for High Speed Civil Transport Aircraft Improved by Neural Network and Regression Methods

A key challenge in designing the new High Speed Civil Transport (HSCT) aircraft is determining a good match between the airframe and engine. Multidisciplinary design optimization can be used to solve the problem by adjusting parameters of both the engine and the airframe. Earlier, an example problem was presented of an HSCT aircraft with four mixed-flow turbofan engines and a baseline mission to carry 305 passengers 5000 nautical miles at a cruise speed of Mach 2.4. The problem was solved by coupling NASA Lewis Research Center's design optimization testbed (COMETBOARDS) with NASA Langley Research Center's Flight Optimization System (FLOPS). The computing time expended in solving the problem was substantial, and the instability of the FLOPS analyzer at certain design points caused difficulties. In an attempt to alleviate both of these limitations, we explored the use of two approximation concepts in the design optimization process. The two concepts, which are based on neural network and linear regression approximation, provide the reanalysis capability and design sensitivity analysis information required for the optimization process. The HSCT aircraft optimization problem was solved by using three alternate approaches; that is, the original FLOPS analyzer and two approximate (derived) analyzers. The approximate analyzers were calibrated and used in three different ranges of the design variables; narrow (interpolated), standard, and wide (extrapolated).

Hopkins, Dale A.↗
DOE OSTI2025

Using Separation-Enhanced Isotope Ratio Mass Spectrometry to Enable Increased Renewable Carbon Content in Transportation Fuels (CRADA 525)

Stable isotope ratio measurements of carbon atoms using isotope ratio mass spectrometry (IRMS) can be an effective tool for quantifying biogenic carbon in co-processed fuels, with results approaching the precision and accuracy of accelerator mass spectrometry (AMS). The lower cost of an IRMS may enable deployment to refineries, improving access and analysis turnaround times (≤2 hours), and, by extension, provide data that can allow process optimization to maximize renewable carbon in desired refinery products. This project explored the integration of chemical separation with IRMS analyses to enable highly detailed tracking of biogenic carbon into fuel product streams separated by boiling point range, chemical class, or specific compound. Forty-nine fuels and fuel components of fossil and biogenic origin, spanning gasoline and diesel boiling point ranges, were received from three refiners and were analyzed for their δ 13 C values via IRMS. Results spanned a 13 C range from ca. 10‰ to 44‰ and reflect materials derived from sustainable sources (e.g., C4 or C3 plants, animal-based pathways, syngas) or from fossil-derived fuels. Common ranges are approximately 18‰ to 9‰ and approximately 30‰ to 20‰ for C4 and C3 plants, respectively, and approximately 34‰ to 24‰ and approximately 70‰ to 33‰ for petroleum-derived fuels and methane, respectively. Fuel-like standards were developed and tested using direct-injection elemental analyzer (EA) IRMS for liquid fuels. This method was compared with the published methods, yielding statistically similar results. Four blend curve sets were produced ranging from 0% to 100% of a fuel containing biogenic carbon, focusing on 0% to 10% biogenic carbon. Linear fits were the most applicable for two of the four blend curve sets; however, two sets were found to exhibit slightly quadratic behavior, which was more pronounced in low biogenic blend samples, necessitating second-order fits. The origin of the slight quadratic behavior remains unclear; however, the discussion points to possible interpretations. CanmetENERGY thoroughly characterized a majority of the samples using one- and two-dimensional gas chromatography (GC and GC×GC, respectively) and other analyses. Selected samples were subjected to solid phase extraction (SPE) for saturate, olefin, aromatic, and polar (SOAP) analysis, and the resulting solvent-diluted fractions containing saturates and aromatics were returned to Pacific Northwest National Laboratory (PNNL), where the solvent was removed via evaporation or physical separation using GC techniques. Characterization and separations provided an understanding of saturate and aromatic content, as well as boiling point ranges for each sample and sample fraction. Samples resulting from SPE were examined using EA-IRMS and gas chromatography combustion IRMS (GC-C-IRMS) analyses. Both approaches suggest that the range in values between end-members can be increased by selecting the paraffinic or aromatic fraction of the end-member or by selecting among individual compounds resulting from GC separation of the paraffinic fractions. Considerable work remains to put these approaches into practice and statistically validate the benefit for using a fraction or individual compound over bulk analysis of a sample. However, initial results suggest that separations provide advantages for samples having blend ratios of less than 10% biogenic blendstocks. 13 C results showed statistically similar biofuel blend results to those obtained at PNNL, although additional work is needed to obtain better reproducibility. Select samples were sent to Los Alamos National Laboratory (LANL) for IRMS measurements and Beta Analytics for AMS measurements. This work suggests that IRMS and AMS yield closely comparable results and in some circumstances, IRMS could serve as a surrogate for AMS. While additional work is needed to better resolve statistical advantages for separations and better show the comparable nature of IRMS and AMS in both the biogenic carbon analysis of bulk chemical classes, initial results from this study suggest that these should be pursued in order to proliferate this approach for quantifying biogenic carbon in transportation fuels to the refinery level, thereby potentially enabling process optimization in co-processing scenarios.

09 BIOMASS FUELS↗
DOE OSTI2026

Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels (Final Scientific/Technical Report)

The project, "Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels," represents a significant advancement in nuclear fuel recycling technology. It integrates cutting-edge multimodal sensor fusion, machine learning (ML), and digital twin (DT) technologies to address challenges in material safeguarding, process optimization, and regulatory compliance for pyroprocessing facilities. This research has significantly enhanced the understanding of pyrochemical fuel recycling processes by developing innovative tools and methodologies. The Multimodal Safeguards Monitoring Unit (MSMU) combines electroanalytical techniques, Raman spectroscopy, and differential thermal analysis (DTA) to enable high-fidelity, near-real-time material accountancy measurements. Machine learning techniques, such as Long Short-Term Memory (LSTM) autoencoders, are utilized to detect anomalies in material balances and sensor data, improving the reliability of safeguards monitoring. Additionally, digital twin technology has been established to provide real-time system-level monitoring and diagnostics, integrating physics-based models with sensor data to optimize process safety and efficiency.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2004

Processing Robustness for A Phenylethynyl Terminated Polyimide Composite

The processability of a phenylethynyl terminated imide resin matrix (designated as PETI-5) composite is investigated. Unidirectional prepregs are made by coating an N-methylpyrrolidone solution of the amide acid oligomer (designated as PETAA-5/NMP) onto unsized IM7 fibers. Two batches of prepregs are used: one is made by NASA in-house, and the other is from an industrial source. The composite processing robustness is investigated with respect to the prepreg shelf life, the effect of B-staging conditions, and the optimal processing window. Prepreg rheology and open hole compression (OHC) strengths are found not to be affected by prolonged (i.e., up to 60 days) ambient storage. Rheological measurements indicate that the PETAA-5/NMP processability is only slightly affected over a wide range of B-stage temperatures from 250 deg C to 300 deg C. The OHC strength values are statistically indistinguishable among laminates consolidated using various B-staging conditions. An optimal processing window is established by means of the response surface methodology. IM7/PETAA-5/NMP prepreg is more sensitive to consolidation temperature than to pressure. A good consolidation is achievable at 371 deg C (700 deg F)/100 Psi, which yields an RT OHC strength of 62 Ksi. However, processability declines dramatically at temperatures below 350 deg C (662 deg F), as evidenced by the OHC strength values. The processability of the IM7/LARC(TM) PETI-5 prepreg was found to be robust.

Hou, Tan-Hung↗
NASA NTRS1996

Processing and Properties of Fiber Reinforced Polymeric Matrix Composites: Processing Robustness of IM7/PETI Polyimide Composites - Part 2

The processability of a phenylethynyl terminated imide (PETI) resin matrix composite was investigated. Unidirectional prepregs were made by coating an N-methylpyrrolidone solution of the amide acid oligomer onto unsized IM7. Two batches of prepregs were used: one was made by NASA in-house, and the other was from an industrial source. The composite processing robustness was investigated with respect to the effect of B-staging conditions, the prepreg shelf life, and the optimal processing window. Rheological measurements indicated that PETI's processability was only slightly affected over a wide range of B-staging temperatures (from 250 C to 300 C). The open hole compression (OHC) strength values were statistically indistinguishable among specimens consolidated using various B-staging conditions. Prepreg rheology and OHC strengths were also found not to be affected by prolonged (i.e., up to 60 days) ambient storage. An optimal processing window was established using response surface methodology. It was found that IM7/PETI composite is more sensitive to the consolidation temperature than to the consolidation pressure. A good consolidation was achievable at 371 C/100 Psi, which yielded an OHC strength of 62 Ksi at room temperature. However, processability declined dramatically at temperatures below 350 C.

Hou, Tan-Hung↗
DOE OSTI2025

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗