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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Discrete Assemblers Utilizing Conventional Motion Systems

An alternative to additive manufacturing is disclosed, introducing an end-to-end workflow in which discrete building blocks are reversibly joined to produce assemblies called digital materials. Described is the design of the bulk-material building blocks and the devices that are assembled from them. Detailed is the design and implementation of an automated assembler, which takes advantage of the digital material structure to avoid positioning errors within a large tolerance. To generate assembly sequences, a novel CAD/CAM workflow is described for designing, simulating, and assembling digital materials. The structures assembled using this process have been evaluated, showing that the joints perform well under varying conditions and that the assembled structures are functionally precise.

Langford, William Kai↗
NASA NTRS2019

A Simple Transient Thermal Test Assembly for Insulation Materials

A simple transient thermal test was developed for evaluating the thermal performance of high-temperature flexible insulation materials in atmospheric pressure air. The test setup was inspired by the test assembly used for evaluating the performance of fire shelters and fire protective clothing. The heating source used was a burner supplied with propane gas that can generate relatively uniform heating over a wide area. The ratio of the in-plane width to thickness of the insulation test sample in the test assembly was selected to be greater than ten so that the heat transfer in the center of the test assembly was nearly one-dimensional. A rigid, thin Inconel plate was used as the septum plate directly exposed to the flame to provide a relatively uniform, known-temperature boundary condition for the test assembly, and to prevent convective heat transfer through the test insulation from the burner. The test sample, flexible alumina paper insulation, was placed between the Inconel plate and a thin titanium witness plate. The overall assembly was further insulated using a combination of rigid and flexible ceramic insulations to minimize heat losses from the periphery of the test assembly. Thermocouples installed on the septum and witness plates and inside the insulation test sample provided temperature measurements at various locations. For the evaluation tests, the Inconel septum plate reached temperatures between 780°C and 850°C for tests with flame exposure durations of 120 sec to 300 sec. The measured temperatures for various tests with similar flame exposure times were repeatable. A one-dimensional numerical heat transfer model of the test assembly was developed. The close agreement between measured and predicted temperatures on the titanium witness plate and inside the insulation test sample indicated that this test may provide a one-dimensional thermal testing capability for evaluation of thermal performance of similar insulations.

Daryabeigi, Kamran↗
NASA NTRSDate not supplied

Enhancing Scalability for FUN3D Rotorcraft Simulations with Yoga: an Overset Grid Assembler

FUN3D, an unstructured grid Navier-Stokes CFD code is capable of overset grid simu- lations, but does not have an internal method for assembling an overset grid system from a group of component grids. FUN3D currently relies on the third party codes Suggar++ and DiRTlib to perform domain assembly and provide intergrid connectivity for overset simulations. Rotorcraft simulations with moving, deforming blades require domain assembly and mesh deformation at each time step. For these simulations, the three primary drivers of computational cost for each time step are: deforming the mesh, performing domain assembly, and performing subiterations of the flow solver. FUN3D exhibits strong and weak scalability for the flow solver subiterations and the mesh deformation. However, FUN3D is currently hardwired directly to the serial version of Suggar++, which has a fixed cost for a given mesh system. Therefore, domain assembly begins to dominate the total cost of each time step as grid systems become larger. An integrated method for parallel domain assembly is presented that addresses scalability for large grid systems. Restructuring within FUN3D to accommodate integrated domain assembly is also discussed, which could enable use of the parallel Suggar++ library.

Cameron T Druyor↗
NASA NTRSDate not supplied

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley↗
DOE OSTI2025

Shaping Peptide Assemblies Using Multifaceted Cyclic Tectons

Constructing distinct biomacromolecular assemblies typically necessitates target-specific selection and engineering of building blocks alongside optimization of assembly conditions. The challenge lies in achieving diverse morphological outcomes using simple, shared modules under identical conditions, a hallmark of natural systems that remains elusive in synthetic approaches. Here, in this work, we present a molecular scaffold-based strategy to instruct the coassembly of the same set of peptides into a variety of nanostructures across multiple dimensions. We create trifaceted cyclic scaffolds to manipulate two pairs of dimeric coiled-coil peptides prior to coassembly. These scaffolds, with addressable and orthogonal modules, allow controlled exposure of their cohesive faces, directing the formation of nanotriangles and fibrillar and lamellar assemblies. By tuning interpeptide arrangements that dictate scaffold geometry, we construct nonstraight fibrils with tunable curvature, which are rarely observed before. Notably, these scaffolds exhibit plasticity in adapting the sizes and orientations of cohesive faces to different assembly morphologies. The resultant nanostructures are consistent with the design and simulation results, demonstrating the reliability and predictability of this approach. Multifaceted cyclic scaffolds bridge the intellectual and physical gaps between building peptides and assemblies, holding promise for endowing various existing assembly systems with high tunability and versatility.

assembly morphology↗
DOE OSTI2024

Unveiling the nanoscale architectures and dynamics of protein assembly with in situ atomic force microscopy

Proteins play a vital role in different biological processes by forming complexes through precise folding with exclusive inter- and intra-molecular interactions. Understanding the structural and regulatory mechanisms underlying protein complex formation provides insights into biophysical processes. Furthermore, the principle of protein assembly gives guidelines for new biomimetic materials with potential applications in medicine, energy, and nanotechnology. Atomic force microscopy (AFM) is a powerful tool for investigating protein assembly and interactions across spatial scales (single molecules to cells) and temporal scales (milliseconds to days). It has significantly contributed to understanding nanoscale architectures, inter- and intra-molecular interactions, and regulatory elements that determine protein structures, assemblies, and functions. This review describes recent advancements in elucidating protein assemblies with in situ AFM. We discuss the structures, diffusions, interactions, and assembly dynamics of proteins captured by conventional and high-speed AFM in near-native environments and recent AFM developments in the multimodal high-resolution imaging, bimodal imaging, live cell imaging, and machine-learning-enhanced data analysis. These approaches show the significance of broadening the horizons of AFM and enable unprecedented explorations of protein assembly for biomaterial design and biomedical research.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Substrate-Directed Dimensional and Phase Control of Peptide Assemblies on Two-Dimensional van der Waals Materials

Understanding and controlling biomolecular self-assembly on van der Waals (vdW) materials has the potential to advance hybrid bioelectronic devices by enabling precise tuning of the interface and modulation of the resulting electronic properties of the biomolecule-vdW heterostructure. However, how surface properties of vdW materials direct biomolecule assembly remains poorly understood. To fill this knowledge gap, we investigated the assembly of a peptide known to assemble into two-dimensional (2D) crystalline films on MoS 2 on three representative vdW surfaces: WS 2 , MoS 2 , and highly oriented pyrolytic graphite (HOPG). Using in situ atomic force microscopy (AFM), we find that assembly is substrate-dependent, resulting in multilayers on WS 2 , monolayers on MoS 2 , and multiple coexisting phases on HOPG. WS 2 exhibits a higher negative charge, strong long-range electrostatic interactions, and extensive hydration layering that may promote multilayer stacking. In contrast, MoS 2 has stronger short-range interactions with the peptides but much weaker long-range interactions and hydration structure, which may favor monolayer formation. Molecular dynamics simulations predict a corresponding switch from monolayer to multilayer aggregates of the adsorbed monomers, reflected in their relative mobilities. On hydrophobic HOPG, the peptides bind most strongly and remain as monomers with high surface mobility. The peptide dimers comprising the basic unit of the crystals are more compact on HOPG, which has a smaller lattice constant than WS 2 or MoS 2 , suggesting strain contributes to stabilizing multiple phases. Our results provide mechanistic insights into how surface charge and hydration structure, and the lattice structure of the substrates governs peptide assembly on vdW materials, offering a framework to rationally control the 2D peptide-vdW heterostructures.

Molecular dynamics simulations↗
DOE OSTI2026

Polymorphism in Self-Assembly of Short Peptoid Sequences

Due to various applications enabled by diverse morphologies of self-assembled sequence-defined polymers, controlling the self-assembly of synthetic peptidomimetics into designed morphologies has emerged as a promising route for the development of bioinspired functional materials. Herein, we report morphological control over the assembly of a series of short peptoids, or poly-N-substituted glycines, that contain asymmetric hydrophobic domains. We demonstrate that the inherent flexibility of amphiphilic peptoid bilayers drives assembly polymorphism, resulting in the coexistence of nanosheets, twisted ribbons, and nanofibers three distinct morphologies. By tuning peptoid molecular interactions through variations in sequence design, solution pH, and temperature, we demonstrate precise control over the twisting and folding of peptoid bilayers, enabling the formation of well-defined nanosheets and nanohelices. Molecular dynamics simulations further unravel how the introduction of asymmetric hydrophobic domains enables the flexibility of peptoid bilayers and results in peptoid assembly polymorphism. By tuning peptoid molecular interactions through heating, we further demonstrate the transformation of nanosheets into nanohelices. We envision that our mechanistic investigation of peptoid assembly polymorphism provides a strong foundation for leveraging peptoid sequences and chemistries to achieve controlled molecular interactions, driving the creation of biomimetic materials with tailored morphologies and functionalities.

assembly polymorphism↗
NASA NTRS2023

MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures

In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.

Robotics↗
DOE OSTI2024

Nanocrystal Assemblies: Current Advances and Open Problems

Here we explore the potential of nanocrystals (a term used equivalently to nanoparticles) as building blocks for nanomaterials, and the current advances and open challenges for fundamental science developments and applications. Nanocrystal assemblies are inherently multiscale, and the generation of revolutionary material properties requires a precise understanding of the relationship between structure and function, the former being determined by classical effects and the latter often by quantum effects. With an emphasis on theory and computation, we discuss challenges that hamper current assembly strategies and to what extent nanocrystal assemblies represent thermodynamic equilibrium or kinetically trapped metastable states. We also examine dynamic effects and optimization of assembly protocols. Finally, we discuss promising material functions and examples of their realization with nanocrystal assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2020

State of the Profession Considerations: NASA Langley Research Center Capabilities / Technologies for Autonomous In-Space Assembly and Modular Persistent Assets

Successfully implementing OSAM into next generation revolutionary observatories requires integrating expertise and technologies in modular space structures, assembly operations, autonomy, and modeling/simulation. LaRC OSAM technologies/capabilities have been presented to inform the Planetary Science and Astrobiology Decadal Survey community of the robust and mature existing capability to support an OSAM based architecture for their next observatory. LaRC Structures and Assembly capabilities enable; a modular telescope architecture, high-performance structural modules, and robotic assembly techniques. LaRC Autonomy capabilities ensure that the robotic assembly will be accomplished in a safe and robust manner and only require humans in a supervisory role. The LaRC toolbox of Modeling and Simulation capabilities that is calibrated using module-level ground testing, will ensure that the performance of the fully assembled observatory, a very large zero-g system that will never be assembled/tested in a gravity environment, meets all performance requirements when it enters into service. Integrating all three LaRC capabilities and including embedded metrology, will enable servicing, repair, instrument upgrades (and/or replacement) while ensuring a very long lifetime for the observatory and providing a return-on-investment that is substantially greater than the initial cost. Further confidence will be achieved as OSAM technologies are validated in a new LaRC OSAM laboratory that allows large-scale collaborative testing of modular hardware, simulation software and algorithms, and autonomous agents.

Large space structures↗
DOE OSTI2025

Structural Characterization of the Platinum Nanoparticle Hydrogen-Evolving Catalyst Assembled on Photosystem I by Light-Driven Chemistry

Directed assembly of abiotic catalysts onto biological redox protein frameworks is of interest as an approach for the synthesis of biohybrid catalysts that combine features of both synthetic and biological materials. In this report, we provide a multiscale characterization of the platinum nanoparticle (NP) hydrogen-evolving catalysts that are assembled by light-driven reductive precipitation of platinum from an aqueous salt solution onto the photosystem I protein (PSI), isolated from cyanobacteria as trimeric PSI. The resulting PSI-NP assemblies were analyzed using a combination of X-ray energy-dispersive spectroscopy (XEDS), high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM), small-angle X-ray scattering (SAXS), and high-energy X-ray scattering with atomic pair distribution function (PDF) analyses. The results show that the PSI-supported NPs are approximately 1.8 nm diameter disk-shaped particles that assemble at discrete sites with 145 Å separation. This separation is too large to be consistent with NP nucleation and growth at a site adjacent to the F B cofactor site. Instead, we suggest a mechanism for NP growth at hydrophobic sites on the PSI stromal surface. The NPs photoreductively assembled on the PSI stromal surface are found to be analogous to the nanostructures produced by successive cycles of atomic layer deposition (ALD) of platinum onto 40 nm porous anodic alumina oxide supports, although the mechanisms for nucleation appear to differ. In conclusion, this work establishes a foundation for the investigation of the reductive assembly of abiotic metal catalysts at sites connected to photochemically reducing equivalent production in PSI.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Lithium–Sulfur Batteries: 3D Printed Tools and Assembly Techniques for Repeatable Lab-Scale Coin Cell Manufacturing

The coin cell form factor has become a standard in energy storage research owing to its relatively low cost, low quantity of requisite electroactive material, fast experimental turnover, and capability to generate publishable quality data. Coin cell assembly at the lab-scale requires precise manual alignment of the many internal components of a cell to yield a properly functioning device. Truly repeatable device assembly presents a significant challenge to the acquisition of reliable data. In this report, we present a three-dimensional (3D) printable design for a coin cell alignment device and describe techniques for a generalized workflow to achieve reproducible coin cell assembly of lithium-based batteries. Standardized assembly techniques using readily accessible, purpose-built tools were demonstrated for labscale production of lithium−sulfur (Li−S) coin cells. Li−S batteries fabricated using the alignment device as well as conductive adhesive incorporated workflows afforded coin cells with up to 35% reduction of assembly times, comparable or better functional cell yields, and improved electrochemical device performance with more consistent and up to 150 mAh/g higher average discharge capacities coupled with Coulombic efficiency increases of up to 2.0% over manually aligned cell assembly techniques.

Batteries↗
DOE OSTI2024

Developmental assembly of multi-component polymer systems through interconnected synthetic gene networks in vitro

Abstract Living cells regulate the dynamics of developmental events through interconnected signaling systems that activate and deactivate inert precursors. This suggests that similarly, synthetic biomaterials could be designed to develop over time by using chemical reaction networks to regulate the availability of assembling components. Here we demonstrate how the sequential activation or deactivation of distinct DNA building blocks can be modularly coordinated to form distinct populations of self-assembling polymers using a transcriptional signaling cascade of synthetic genes. Our building blocks are DNA tiles that polymerize into nanotubes, and whose assembly can be controlled by RNA molecules produced by synthetic genes that target the tile interaction domains. To achieve different RNA production rates, we use a strategy based on promoter “nicking” and strand displacement. By changing the way the genes are cascaded and the RNA levels, we demonstrate that we can obtain spatially and temporally different outcomes in nanotube assembly, including random DNA polymers, block polymers, and as well as distinct autonomous formation and dissolution of distinct polymer populations. Our work demonstrates a way to construct autonomous supramolecular materials whose properties depend on the timing of molecular instructions for self-assembly, and can be immediately extended to a variety of other nucleic acid circuits and assemblies.

Science & Technology - Other Topics↗
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 OSTI2024

Test Stand Functional Requirements for Testing MQXFA Magnets and Q1/Q3 Cryostat Assemblies (Rev.3)

This document specifies test stand requirements for testing the High Luminosity LHC (HL-LHC, or HiLumi LHC) MQXFA magnets and LQXFA/B cryostat assemblies. Total of 12 (3 pre-series, 7 series production and 2 re-work) of these cryostat assemblies are expected to be fabricated and delivered to CERN by the U.S. HL-LHC Accelerator Upgrade Project (US HL-LHC AUP) as part of the U.S. contributions to the LHC High Luminosity Upgrade. These cryostat assemblies are the quadrupole magnetic components of the HL-LHC Q1 (LQXFA) and Q3 (LQXFB) inner triplet optical elements in front of the interactions points 1 (ATLAS) and 5 (CMS). One LMQXFA cold mass is installed in each cryostat assembly and each cold mass consists of two MQXFA quadrupole magnets. MQXFA, LMQXFA and LQXFA/B functional requirements are specified in [1,2,3].MQXFA magnets will be tested at BNL Vertical Magnet Test Facility (VMTF) and 12 cryostat assembly tests planned at Fermilab’s Horizontal Magnet Test Facility (HMTF). This document specifies the test stand functional requirements for testing MQXFA magnets and LQXFA/B cryostat assemblies.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Robotic Assembly of SRF Cavity Pair

Superconducting Radio Frequency (SRF) cavities for particle accelerators require tight tolerances, ultrahigh vacuum, and strict cleanliness during assembly. As in the semiconductor industry, defects such as particles and residues are deleterious to performance, possibly rendering a cavity unfit for use. This problem is addressed primarily through cleanroom assembly during sensitive steps and rigorous chemical processing to prevent and remove such defects. Human workers are often the largest source of contamination, even with proper gowning and practices. The semiconductor industry has long integrated robots in cleanroom operation, but this has not occurred for SRF cavity production; SRF cavities, unlike wafers, are complex shapes, require more hands-on mechanical assembly, and are low-volume production items. At Jefferson Laboratory, a co-operative robot (cobot) has been setup to overcome these problems. Cobots are safe for use alongside human workers and can integrate new tools such as a 3D camera part detection and gripper for item manipulation. Therefore, cobots represent a promising avenue for reducing particulate generated during a variety of assembly tasks. A mockup of a cavity pair and coupler was setup and the cobot programmed to automatically pick up the coupler and place on the mating cavity flange. Particle counting methods were setup to measure human vs cobot assembly particulate generation inside a cavity mockup. Other potential uses will be discussed for further improving SRF cavity assembly steps, where a cobot can replace or assist a human operator, and what potential gains are expected.

Duzik, Adam [Thomas Jefferson National Accelerator↗
DOE OSTI2026

NuMI Graphite Target Fin Removal Assembly

Materials scientists want to study the irradiated graphite target from the Neutrino at the Main Injector (NuMI) beam line. In order to gather these irradiated graphite fins from the target canister, it will have to be done remotely. Therefore, a removal assembly will need to be created in order to do this efficiently and well. This project aims to make progressive steps towards deploying the final target removal assembly. Furthermore, calculations related to the removal assembly design were done, and tests were planned to discover further information about the feasibility of this design. The main result from this project is the deflection of the cantilever arm, which is 0.354 inches due to the weight of the beam and cutting tool. Additionally, more results of this project are the testing assembly CAD model and the feasibility of design. This project concludes that there is still more work that needs to be done for the removal assembly to be deployed, but there were foundational steps that were made in the implementation of this design. Finally, there should be further steps and tests to determine the feasibility of this removal assembly.

Malovski, Azra [NIU, DeKalb]↗