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NASA NTRS2002

Superfinished Surfaces for Power Transfer Systems Improvement

The continuous demands for high performance and lightweight power train systems resulted in requirements for higher power density gearing systems. However, increasing the load bearing capacity of the gear teeth, without increasing size, places stringent requirements upon metallurgy, dimensional control, and surface finish of the final products. In order to operate the mating parts near the upper bounds of their theoretical design envelope, manufacturing processes are required that are capable of improving the fatigue life and load bearing capacity of precision parts, while producing the required geometric accuracy. Results of the recent experimental studies indicate that the super finishing process is able to achieve these goals. This paper will review the results of our continuing evaluation of the super finish process as applied to aerospace gearing. Two separate evaluations were performed on gears to examine the effects of super finishing on resistance to both pitting and contact fatigue. For the reported experiments, both conventional and super finished test gears were simultaneously manufactured using the same process and the same heat lot of materials. This paper will also provide a brief description of the manufacturing technology used to achieve the results and will compare the results with other published data. In addition, this paper presents a couple of off-the-shelf manufacturing technologies that have been successfully used to super finish test specimens and will provide a glimpse of other emerging super finishing technologies. This is a US Army Manufacturing Technology project. The project was sponsored by the Aviation and Missiles Command (AMCOM) and was being managed and conducted by IIT Research Institute.

Niskanen, Paul↗

NASA NTRS1977

Role of the adrenocortical reaction to physical load in increase in the working capacity of the body

The maximal duration of swimming by rats with a load of 3% of their body weight increased after 5 weeks of training. This time did not increase in animals receiving dexamethasone in the process of training. The blood corticosterone level of these rats with the maximal load increased less than that of animals trained without administration of dexamethasone.

Viru, A. A.↗

DOE OSTI2026

Evaluation of the Room Temperature Field Quality Measurements of HL-LHC MQXFA Magnet Assemblies

As a member of the multi-lab U.S. High Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP), Lawrence Berkeley National Laboratory (LBNL) is assembling high-field Nb3Sn low-beta MQXFA quadrupole magnets for eventual installation at CERN as part of the HL-LHC upgrade. Each magnet undergoes room temperature magnetic measurements at two points during the assembly process: once after completion of the coil pack sub-assembly and once after the magnet is fully assembled and pre-loaded. Beyond its use to verify that each magnet assembly can meet operational requirements, the data from this two-stage measurement process allow for investigation into the impact of the pre-loading operation on field quality. Recent measurements on magnet rebuilds as well as exploratory coil pack reconfigurations also provide an opportunity to see in isolation the effects of changes to a magnet’s coil selection or coil layout. In this work, we present the magnetic measurement results of MQXFA magnets assembled or currently in process, focusing particularly on magnets with data corresponding to multiple builds, and discuss trends and insights which may be beneficial for the remaining MQXFA magnet production or for future Nb3Sn accelerator magnets.

Doyle, Jennifer [LBNL, Berkeley] (ORCID:0009000079↗

DOE OSTI2023

Evaluation Of Glass Density to Support the Estimation of Fissile Mass Loadings in Sludge Batch 10 Glasses

Per a directive from the Department of Energy Savannah River Operations Office (DOE-SR) in 2008, the fissile mass loading concentration must remain below 897 g/m 3 in each high-level waste (HLW) glass canister produced by the Defense Waste Processing Facility (DWPF). To support Sludge Batch 5 (SB5) processing, the Savannah River National Laboratory (SRNL) developed a technical basis that facilitates the evaluation of fissile mass loading of the glass product. The calculation is based on the iron (Fe) concentration in the glass as determined by measurements from the Slurry Mix Evaporator acceptability analysis as well as the glass density. In April 2022, a subsequent DOE-SR directive increased the fissile mass loading limit to 2500 g/m 3 beginning with Sludge Batch 11. Thus, the 897 g/m 3 limit still applies to Sludge Batch 10 (SB10) processing. For SB5 through initial Sludge Batch 9 (SB9) processing prior to coupled operation with the Salt Waste Processing Facility (SWPF), SRNL provided DWPF a bounding glass density value that was based on a statistical evaluation of density measurements. To eliminate the need for experimental work, a composition-based density model for HLW glasses was developed at SRNL in 2019. The objective of this report is to present the bounding glass density determined with the composition-based density model for SB10 sludge-only (SO) and coupled processing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Evaluation of Glass Density to Support the Estimation of Fissile Mass Loadings in Sludge Batch 10 Glasses

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Palladium-Percolated Networks Enabled by Low Loadings of Branched Nanorods for Enhanced H 2 Separations

Nanoparticles (NPs) at high loadings are often used in mixed matrix membranes (MMMs) to improve gas separation properties, but they can lead to defects and poor processability that impede membrane fabrication. Herein, it is demonstrated that branched nanorods (NRs) with controlled aspect ratios can significantly reduce the required loading to achieve superior gas separation properties while maintaining excellent processability, as demonstrated by the dispersion of palladium (Pd) NRs in polybenzimidazole for H 2 /CO 2 separation. Increasing the aspect ratio from 1 for NPs to 40 for NRs decreases the percolation threshold volume fraction by a factor of 30, from 0.35 to 0.011. An MMM with percolated networks formed by Pd NRs at a volume fraction of 0.039 exhibits H 2 permeability of 110 Barrer and H 2 /CO 2 selectivity of 31 when challenged with simulated syngas at 200 °C, surpassing Robeson's upper bound. In conclusion, this work highlights the advantage of NRs over NPs and nanowires and shows that right-sizing nanofillers in MMMs is critical to construct highly sieving pathways at minimal loadings. In conclusion, this work paves the way for this general feature to be applied across materials systems for a variety of chemical separations.

36 MATERIALS SCIENCE↗

NASA NTRS2012

Some Examples of the Relations Between Processing and Damage Tolerance

Most structures made of laminated polymer matrix composites (PMCs) must be designed to some damage tolerance requirement that includes foreign object impact damage. Thus from the beginning of a part s life, impact damage is assumed to exist in the material and the part is designed to carry the required load with the prescribed impact damage present. By doing this, some processing defects may automatically be accounted for in the reduced design allowable due to these impacts. This paper will present examples of how a given level of impact damage and certain processing defects affect the compression strength of a laminate that contains both. Knowledge of the impact damage tolerance requirements, before processing begins, can broaden material options and processing techniques since the structure is not being designed to pristine properties.

Nettles, Alan T.↗

DOE OSTI2020

Ammonia Fiber Expansion (AFEX) Pretreatment of Lignocellulosic Biomass

Lignocellulosic materials are plant-derived feedstocks, such as crop residues (e.g., corn stover, rice straw, and sugar cane bagasse) and purpose-grown energy crops (e.g., miscanthus, and switchgrass) that are available in large quantities to produce biofuels, biochemicals, and animal feed. Plant polysaccharides (i.e., cellulose, hemicellulose, and pectin) embedded within cell walls are highly recalcitrant towards conversion into useful products. Ammonia fiber expansion (AFEX) is a thermochemical pretreatment that increases accessibility of polysaccharides to enzymes for hydrolysis into fermentable sugars. These released sugars can be converted into fuels and chemicals in a biorefinery. Here, we describe a laboratory-scale batch AFEX process to produce pretreated biomass on the gram-scale without any ammonia recycling. The laboratory-scale process can be used to identify optimal pretreatment conditions (e.g., ammonia loading, water loading, biomass loading, temperature, pressure, residence time, etc.) and generates sufficient quantities of pretreated samples for detailed physicochemical characterization and enzymatic/microbial analysis. The yield of fermentable sugars from enzymatic hydrolysis of corn stover pretreated using the laboratory-scale AFEX process is comparable to pilot-scale AFEX process under similar pretreatment conditions. This paper is intended to provide a detailed standard operating procedure for the safe and consistent operation of laboratory-scale reactors for performing AFEX pretreatment of lignocellulosic biomass.

09 BIOMASS FUELS↗

NASA NTRS1984

Off-axis tensile properties and fracture in a unidirectional graphite/polyimide composite (Celion 6000/PMR 15)

Tensile properties of unidirectional Celion 6000 graphite/PMR 15 polyimide composites prepared by hot molding and cold molding processes were measured at room temperature and 316 C, the upper use temperature of the polyimide resin, at both 45 and 90 deg to the fiber axis. The resulting fractures were characterized by scanning electron microscopy and materialographic techniques. Variation in tensile properties with processing history occurred in the elastic modulus and strain to failure for specimens loaded at 90 deg at 316 C, and in the fracture stress, and hence the in-plane shear stress, for those loaded at 45 deg at room temperature. Significant plastic deformation was observed in the 45 deg orientation at 316 C for material produced by both processing methods. In general, fracture occurred by both failure within the matrix and at the fiber-matrix interface; the degree of interfacial failure increased with temperature. Secondary cracking below the primary fracture surface was also observed.

Harper, J.↗

NASA NTRS2019

Ammonia Stability in a Simulated Trace Contaminant Rich Cabin Environment

The off-gassing of ammonia from hardware and metabolic sources presents a unique challenge to trace contaminant control system design, driving process flowrates to meet crewed air quality requirements. Accurately simulating representative trace contaminant cabin loads during ground testing is necessary to validate component design as well as understand potential contaminant propagation across life-support system process interface boundaries. This effort is complicated by the observed temporal concentration instability of gaseous ammonia in ground test chambers. To this end, ammonia concentration decay rates were characterized under controlled environmental conditions to better understand underlying phenomena and quantify incidental mass losses. The suspected chemical interaction between ammonia and trace acetaldehyde was investigated and its effect on species quantification was examined by both gas chromatography-mass spectrometry and Fourier-transform infrared spectroscopy. Recommendations for ground test procedures were made in order to best compensate for undesirable ammonia mass losses and mitigate test artifacts.

Kayatin, Matthew J.↗

NASA NTRSDate not supplied

Acquisition and Processing of Passive Thermography Fatigue Test Data

Passive thermography is a large area inspection technique and is commonly used during fatigue loading of composite structures. Passive thermography allows for real time tracking of damage. This provides an accurate assessment of the damage progression as a function of load cycles and determines when the loading is stopped for ultrasonic or X-ray CT evaluations for detail damage assessment through-the-thickness. In addition, if new areas of damage growth are detected, with passive thermography, then those areas are additionally inspected with ultrasound or X-ray CT. A custom developed passive thermography inspection system for fatigue loading is presented. Passive thermography of damage progression is compared to ultrasound inspections as a function of the fatigue cycles. Discussion is made on processing of the thermal data for periodic and non-periodic thermal responses.

Thermal nondestructive evaluation↗

NASA NTRS2021

The Micro‐Macro Coupling of Mass‐Loading in Symmetric Magnetic Reconnection With Cold Ions

We investigate how magnetic reconnection is influenced by an inflow of a dense cold ion population. We compare two 2.5D Particle-In-Cell simulations, one containing the cold population and one without. We find that the cold population influences the reconnection process on both global and kinetic scales, and that the dominant contribution can be explained through mass-loading. We provide an analysis of how these multiscale changes are related through kinetic processes in the ion diffusion region, the so-called micro-macro coupling of mass-loading. The inertia of the cold ion population is found to be the significant link that connects the changes on different scales. The cold and warm populations exhibit counter streaming behavior when and after the ion diffusion region reorganizes itself in response to the arrival of the cold population. This signature of the cold population should be observable by spacecraft observatories such as MMS.

Magnetic reconnection↗

NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development. Currently there is no fully coupled computational tool to analyze this fluid/structure interaction process. The objective of this study was to develop a fully coupled aeroelastic modeling capability to describe the fluid/structure interaction process during the transient nozzle operations. The aeroelastic model composes of three components: the computational fluid dynamics component based on an unstructured-grid, pressure-based computational fluid dynamics formulation, the computational structural dynamics component developed in the framework of modal analysis, and the fluid-structural interface component. The developed aeroelastic model was applied to the transient nozzle startup process of the Space Shuttle Main Engine at sea level. The computed nozzle side loads and the axial nozzle wall pressure profiles from the aeroelastic nozzle are compared with those of the published rigid nozzle results, and the impact of the fluid/structure interaction on nozzle side loads is interrogated and presented.

Wang, Ten-See↗

NASA NTRS1995

Mechanotransduction and the functional response of bone to mechanical strain

Mechanotransduction plays a crucial role in the physiology of many tissues including bone. Mechanical loading can inhibit bone resorption and increase bone formation in vivo. In bone, the process of mechanotransduction can be divided into four distinct steps: (1) mechanocoupling, (2) biochemical coupling, (3) transmission of signal, and (4) effector cell response. In mechanocoupling, mechanical loads in vivo cause deformations in bone that stretch bone cells within and lining the bone matrix and create fluid movement within the canaliculae of bone. Dynamic loading, which is associated with extracellular fluid flow and the creation of streaming potentials within bone, is most effective for stimulating new bone formation in vivo. Bone cells in vitro are stimulated to produce second messengers when exposed to fluid flow or mechanical stretch. In biochemical coupling, the possible mechanisms for the coupling of cell-level mechanical signals into intracellular biochemical signals include force transduction through the integrin-cytoskeleton-nuclear matrix structure, stretch-activated cation channels within the cell membrane, G protein-dependent pathways, and linkage between the cytoskeleton and the phospholipase C or phospholipase A pathways. The tight interaction of each of these pathways would suggest that the entire cell is a mechanosensor and there are many different pathways available for the transduction of a mechanical signal. In the transmission of signal, osteoblasts, osteocytes, and bone lining cells may act as sensors of mechanical signals and may communicate the signal through cell processes connected by gap junctions. These cells also produce paracrine factors that may signal osteoprogenitors to differentiate into osteoblasts and attach to the bone surface. Insulin-like growth factors and prostaglandins are possible candidates for intermediaries in signal transduction. In the effector cell response, the effects of mechanical loading are dependent upon the magnitude, duration, and rate of the applied load. Longer duration, lower amplitude loading has the same effect on bone formation as loads with short duration and high amplitude. Loading must be cyclic to stimulate new bone formation. Aging greatly reduces the osteogenic effects of mechanical loading in vivo. Also, some hormones may interact with local mechanical signals to change the sensitivity of the sensor or effector cells to mechanical load.

Non-NASA Center↗

DOE OSTI2022

Tailoring compatibilization potential of maleic anhydride–grafted polypropylene by sequential rheochemical processing of polypropylene and polyamide 66 blends

Reactive compatibilization of immiscible polymer blends using a preferred compatibilizer leaves the following question: How much loading of a compatibilizer is good enough and what maximum properties can be achieved? A good understanding of the process can help solve the reutilization of mixed waste plastics. Here, the reactive compatibilization of polypropylene-graft-maleic anhydride (PP-g-MAH) on polypropylene/polyamide 66 (PP/PA66) blends is quantitatively assessed using thermorheological, microoptical, spectroscopic, and x-ray scattering-based characterization tools. The overall compositions of all PP(60%)/PA66(30%)/PP-g-MAH(10%) blends are kept constant while systematically controlling the degree of the chemical reaction by varying the sequential addition of PP-g-MAH to the melt mixture. The first feeding of PP-g-MAH (x%, 0 ≤ x ≤ 10) is conducted at 280°C and the second feeding of (10–x)% is at 200°C. During the first step, a larger amount of chemical activity is observed up to 4%–6% addition of PP-g-MAH. Furthermore, the constant chemical composition allows a systematic comparison of the compatibilizer-dependent thermal, rheological, morphological, and mechanical properties. With an increased degree of interfacial reaction, the size of dispersed PA66 domains decreases to register improved interfacial adhesion with the PP matrix, yielding enhanced Young's modulus and absolute failure strength of the isotropic matrix.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Shape Memory Characteristics of Ti(sub 49.5)Ni(sub 25)Pd(sub 25)Sc(sub 0.5) High-Temperature Shape Memory Alloy After Severe Plastic Deformation

A Ti(49.5)Ni25Pd25Sc(0.5) high-temperature shape memory alloy is thermomechanically processed to obtain enhanced shape-memory characteristics: in particular, dimensional stability upon repeated thermal cycles under constant loads. This is accomplished using severe plastic deformation via equal channel angular extrusion (ECAE) and post-processing annealing heat treatments. The results of the thermomechanical experiments reveal that the processed materials display enhanced shape memory response, exhibiting higher recoverable transformation and reduced irrecoverable strain levels upon thermal cycling compared with the unprocessed material. This improvement is attributed to the increased strength and resistance of the material against defect generation upon phase transformation as a result of the microstructural refinement due to the ECAE process, as supported by the electron microscopy observations.

Atli, K. C.↗

DOE OSTI2025

Divertor Plasma Detachment Control Neural Network

DivControlNN is a state-of-the-art software tool that leverages advanced machine learning techniques to predict and control divertor plasma behavior in fusion reactors. Plasma, a highly energetic and electrically charged gas, requires meticulous management to protect reactor components and maintain optimal energy production. Conventional simulation methods, although extremely detailed, typically demand extensive computational time-making them unsuitable for real-time control scenarios. DivControlNN addresses this challenge by learning from tens of thousands of high-fidelity simulations, thereby creating a rapid surrogate model that can deliver near-instantaneous predictions. At the core of its functionality is a sophisticated technique known as latent space mapping, which condenses complex, high-dimensional plasma data into a compact, lower-dimensional representation. This streamlined representation enables the system to quickly forecast essential plasma properties and determine the precise conditions required for effective detachment. Detachment is a crucial process in which the plasma is cooled before reaching the divertor plates, thereby reducing heat loads and mitigating material erosion. In recent experiments conducted on the KSTAR tokamak in South Korea, DivControlNN successfully guided the detachment process without any fine-tuning-even when applied to a new tungsten divertor configuration. By achieving a computational speed-up of over one hundred million times compared to traditional simulation methods while maintaining low prediction errors, DivControlNN stands to significantly enhance real-time control and diagnostic capabilities in future fusion reactors. This breakthrough paves the way for safer, more reliable reactor operation and represents a major advancement toward realizing fusion energy as a practical, sustainable, and clean power source.

Xu, Xueqiao [Lawrence Livermore National Laborator↗