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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 NTRS1985

Rapid adhesive bonding and field repair of aerospace materials

Adhesive bonding in the aerospace industry typically utilizes autoclaves or presses which have considerable thermal mass. As a consequence, the rates of heatup and cooldown of the bonded parts are limited and the total time and cost of the bonding process are often relatively high. Many of the adhesives themselves do not inherently require long processing times. Bonding could be performed rapidly if the heat was concentrated in the bond lines or at least in the adherends. Rapid Adhesive Bonding concepts are developed to utilize induction heating techniques to provide heat directly to the bond line and/or adherends without heating the entire structure, supports, and fixtures of a bonding assembly. Bonding times for specimens can be cut by a factor of 10 to 100 compared to standard press or autoclave bonding. The development of Rapid Adhesive Bonding for lap shear specimens (per ASTM D1002 and D3163), for aerospace panel or component bonding, and for field repair needs of metallic and advanced fiber reinforced polymeric-matrix composite structures is reviewed. Equipment and procedures are described for bonding and repairing thin sheets, simple geometries, and honeycomb core panels.

Stein, B. A.↗
NASA NTRSDate not supplied

Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗
NASA NTRS2026

Application of Energy-efficient Electromagnetic Melt-Processing for the Upcycling of Recycled Polyphenylene Sulfide into Multifunctional Segregated Nanocomposites

Polyphenylene sulfide (PPS) is widely used in structural and functional composites because of its thermal stability, chemical resistance, and mechanical strength. As circular manufacturing becomes increasingly important, extending the service life of recycled PPS (rPPS) is essential. However, conventional high-temperature reprocessing accelerates thermo-oxidative degradation, reducing recycled composite performance. This study proposes a rapid and potentially energy-saving upcycling strategy for rPPS using electromagnetic (EM) melt-processing to form segregated carbon nanotube (CNT) networks and produce EM-responsive nanocomposites. The aim was to determine whether CNT-assisted EM heating could reduce polymer degradation while improving multifunctional properties at ultralow filler loadings. rPPS micropellets were coated with CNTs by ball milling to create conductive shells, then compacted into green bodies (GBs) and selectively melted by rapid EM irradiation. Structural, electrical, mechanical, rheological, and electromagnetic interference (EMI) shielding properties were evaluated. Electrical percolation occurred at an ultralow CNT loading of 0.08 wt%, with conductivity reaching (1.24 ± 0.74) × 10 -5 S⋅m -1 at 0.1 wt%. At this concentration, tensile strength and modulus increased by 72% and 99%, respectively. At ~ 0.7 mm thickness, X-band EMI shielding effectiveness reached 6 dB for GBs and 3 dB after EM processing. This shows that EM melt-processing upcycles rPPS into high-performance multifunctional nanocomposites with minimum thermal degradation.

recycled↗
DOE OSTI2025

Microwave-Mediated Extraction of Critical Metals from LED E-Waste

This study introduces a microwave-assisted technique for extracting critical minerals from LED electronic waste. The process begins with microwave irradiation, which thermally decomposes the LED’s plastic lens into a brittle, charred residue. During this stage, the LED chip undergoes deflagration—being rapidly ejected from the reflective cavity and becoming embedded within the decomposed lens material. Consequently, the chip is encapsulated in the resulting charred residue. This composite, consisting of the charred lens and the LED chip, can be easily separated from the metallic pins (Fe, Ni, Ag), which remain almost undamaged. Subsequent calcination of the charred material in air exposes the materials making up the LED chip, which contain critical metals (e.g., Ga, As, In, Y, Au). These metals are then extracted through a two-step acid leaching process involving aqua regia followed by hot concentrated hydrochloric acid, yielding them in potentially recoverable forms. The synergistic effect of microwave irradiation and acid treatment achieves an average extraction efficiency of 96% for critical metals. Notably, this approach enables complete and loss-free recovery of the LED chip, offering a practical and efficient solution for LED e-waste recycling.

Bourlinos, Athanasios B.↗
NASA NTRS2003

Microelectromechanical System (MEMS) Device Being Developed for Active Cooling and Temperature Control

High-capacity cooling options remain limited for many small-scale applications such as microelectronic components, miniature sensors, and microsystems. A microelectromechanical system (MEMS) using a Stirling thermodynamic cycle to provide cooling or heating directly to a thermally loaded surface is being developed at the NASA Glenn Research Center to meet this need. The device can be used strictly in the cooling mode or can be switched between cooling and heating modes in milliseconds for precise temperature control. Fabrication and assembly employ techniques routinely used in the semiconductor processing industry. Benefits of the MEMS cooler include scalability to fractions of a millimeter, modularity for increased capacity and staging to low temperatures, simple interfaces, limited failure modes, and minimal induced vibration. The MEMS cooler has potential applications across a broad range of industries such as the biomedical, computer, automotive, and aerospace industries. The basic capabilities it provides can be categorized into four key areas: 1) Extended environmental temperature range in harsh environments; 2) Lower operating temperatures for electronics and other components; 3) Precision spatial and temporal thermal control for temperature-sensitive devices; and 4) The enabling of microsystem devices that require active cooling and/or temperature control. The rapidly expanding capabilities of semiconductor processing in general, and microsystems packaging in particular, present a new opportunity to extend Stirling-cycle cooling to the MEMS domain. The comparatively high capacity and efficiency possible with a MEMS Stirling cooler provides a level of active cooling that is impossible at the microscale with current state-of-the-art techniques. The MEMS cooler technology builds on decades of research at Glenn on Stirling-cycle machines, and capitalizes on Glenn s emerging microsystems capabilities.

Beach, Duane E.↗
NASA NTRS2018

Overview of the RCAP Presented at the ISRU Thermal Integration Meeting

An In-Situ Resource Utilization (ISRU) mission has been proposed for Mars. The ISRU mission would process Oxygen from the Carbon Dioxide in the Martian atmosphere or create Methane and Oxygen from the Martian soil and atmosphere. The Rapid Cycle Adsorption Pump (RCAP) is a proposed technology for Carbon Dioxide separation from residual gases (mainly Nitrogen and Argon) and pressurization for downstream chemical processing from the Martian atmosphere. The RCAP works by using a temperature swing adsorption cycle. We talk about the current RCAP technology development efforts at NASA (modeling, manufacturing, testing, and adsorbent development) and discuss the thermal challenges that are specific to this technology.

Iannetti, Anthony↗
DOE OSTI2025

Microwave-Assisted Reactive CO 2 Capture with the SrCO 3 -Graphite System

This study details the initial development of a microwave heat-driven reactive CO 2 capture (RCC) process using the SrO/SrCO 3 cycle and graphitic carbon to absorb ppm-levels of CO 2 from humidified room temperature air and selectively convert it into CO. By combining first-principles density functional theory (DFT) simulations with thermogravimetric analysis (TGA) and X-ray diffraction (XRD) verification, it is demonstrated that SrO spontaneously absorbs moisture to generate Sr(OH) 2 followed by Sr(OH) 2 *1H 2 O, which then can spontaneously react with atmospheric levels of CO 2 to form SrCO 3 . The resulting SrCO 3 can then react with solid carbon at elevated temperatures to selectively produce CO and regenerate SrO. Graphitic carbon is an excellent microwave absorber that can quickly generate temperatures approaching 1000 °C and then cool to room temperature within minutes, potentially allowing for integration with intermittent electricity. It is shown that using microwaves to selectively heat a mixture of graphitic carbon and SrCO 3 produced CO with 85 ± 3% selectivity and stable performance over ten cycles. The rapid heating for release and room temperature CO 2 uptake processes appeared to prevent performance loss from particle sintering typically observed with traditional thermal systems. In conclusion, these results demonstrate a new RCC approach that adds to the growing number of potential technologies available for converting CO 2 to useful chemicals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1975

Proposed geomagnetic control of semiannual waves in the mesospheric zonal wind

The polar semiannual oscillation in zonal wind explains midwinter weakening of the polar vortex and the relatively short stratospheric and mesospheric summer easterlies. The phase of the wind oscillation is equinoctial, as is the phase of the semiannual component in magnetic storm activity. For a given altitude, the contours of amplitude of the semiannual wind oscillation have less variability in geomagnetic than in geographic coordinates. It is suggested that the polar wind oscillations are caused by the semiannual maxima in magnetic storm activity, which lead to electron dissociation of O2 into O, in turn increasing ozone more rapidly than the dissociation of N2 destroys ozone, and inducing a semiannual variation in the thermal and wind fields. This implies that geomagnetic processes may cause or affect the development of sudden warmings. As the tropical semiannual wind oscillation is symmetric about the geomagnetic equator, the same processes may also influence the location of the tropical wind wave.

Belmont, A. D.↗
NASA NTRS1985

Utilization of satellite cloud information to diagnose the energy state and transformations in extratropical cyclones

An important component of the research was a continuing investigation of the impact of latent release on extratropical cyclone development. Previous efforts to accomplish this task have focused on the energy balance and the vertical motion field of an intense winter extratropical cyclone over the United States. During this fiscal year researchers turned their attention to a more fundamental diagnostic variable, the height tendency. Central to this effort is the use of a modified form of the quasi-geostrophic height tendency equation, in which geostrophic wind components have been replaced by observed winds and a latent heat release term has been added. This methodology was adopted to produce a simple diagnostic model which retains the essential mechanisms of quasi-geostrophic theory but more faithfully describes observed wave development when the Rossby Number approaches and exceeds 0.5. Results to date indicate that the new model yields height tendencies that are superior to those obtained from the quasi-geostrophic formulation and are sufficiently close to the observed tendencies to be a useful tool for diagnosing the principle large-scale forcing mechanisms in th e700-300 mb layer. Of the three forcing terms included in the new model, vortity advection is in general dominant. The most persistent challenge to this dominance is made by the thermal advection. On the whole, latent heat release plays a secondary role. Finally, during the rapid intensification observed for this cyclone, all three processes complement each other in forcing height falls.

Smith, P. J.↗
NASA NTRS2008

Low Power, Wide Dynamic Range Carbon Nanotube Vacuum Gauges

This slide presentation presents carbon nanotube vacuum pressure sensor gauges that operate at low power and exhibit a wide-dynamic range based on microelectromechanical systems (MEMS) technology. The fabrication facility, and the formation process are shown. Pressure sensitivity was found to increase rapidly as the bias power was increased. In addition, by etching part of the thermal SiO2 beneath the tubes and minimizing heat conduction through the substrate, pressure sensitivity was extended toward lower pressures. Results are compared to a conventional thin film meander resistor, which was fabricated and whose pressure response was also measured for comparative purposes.

JEOL E-beam aligner↗
NASA NTRS1983

Constraints on rift thermal processes from heat flow and uplift

The implications of heat flow data available from five major Cenozoic continental rift systems for the processes of continental rifting are discussed, and simple thermal models of lithospheric thinning which predict uplift are used to further constrain the thermal processes in the lithosphere during rifting. Compilations of the heat flow data are summarized and the salient results of these compilations are briefly discussed. The uplift predictions of the slow and rapid thinning models, in which thinning is assumed to occur at a respectively slower and faster rate than heat can be conducted into the lithosphere, are presented. Comparison of uplift rates with model results indicates that the lithosphere is in a state between the two models. While uplift is predicted to continue after thinning has ceased due to thermal relaxation of the lithosphere, the rapid thinning model is always predicted to apply to surface heat flow, and an anomaly in this flow is not predicted to develop until after thinning has stopped.

Morgan, P.↗
NASA NTRS1974

Proposed geomagnetic control of semiannual waves in the mesospheric zonal wind

The polar semiannual oscillation in zonal wind can explain midwinter weakening of the polar vortex and the relatively short stratospheric and mesospheric summar easterlies. The phase of the wind oscillation is equinoctial, as is the phase of the semiannual component in magnetic storm activity. For a given altitude, the contours of amplitude of the semiannual wind oscillation have less variability in geomagnetic than in geographic coordinates. It is suggested that polar wind oscillations are caused by the semiannual maxima in magnetic storm activity which lead to electron dissociation of O2 into O, in turn increasing ozone more rapidly than the dissociation of N2 destroys ozone, and thereby inducing a semiannual variation in the thermal and wind fields. This implies that geomagnetic processes may cause or affect the development of sudden warmings. As the tropical semiannual wind oscillation is symmetric about the geomagnetic equator, the same processes may also influence the location of the tropical wind wave.

Belmont, A. D.↗
NASA NTRS1986

Radio wavelength observations of magnetic fields on active dwarf M, RS CVn and magnetic stars

The dwarf M stars, YZ Canis Minoris and AD Leonis, exhibit narrow-band, slowly varying (hours) microwave emission that cannot be explained by conventional thermal radiation mechanisms. The dwarf M stars, AD Leonis and Wolf 424, emit rapid spikes whose high brightness temperatures similarly require a nonthermal radiation process. They are attributed to coherent mechanisms such as an electron-cyclotron maser or coherent plasma radiation. If the electron-cyclotron maser emits at the second or third harmonic gyrofrequency, the coronal magnetic field strength equals 250 G or 167 G, and constraints on the plasma frequency imply an electron density of 6 x 10 to the 9th/cu cm. Radio spikes from AD Leonis and Wolf 424 have rise times less than or equal to 5 ms, indicating a linear size of less than or equal to 1.5 x 10 to the 8th cm, or less than 0.005 of the stellar radius. Although Ap magnetic stars have strong dipole magnetic fields, they exhibit no detectable gyroresonant radiation, suggesting that these stars do not have hot, dense coronae. The binary RS CVn star UX Arietis exhibits variable emission at 6 cm wavelength on time scales ranging from 30 s to more than one hour.

Lang, Kenneth R.↗
NASA NTRS1987

SiO cooling instability in the envelopes of cool giant stars

In the outer atmospheres of oxygen-rich giant and supergiant stars, the formation of the silicon monoxide molecule not only represents a first step toward the production of dust but may also produce an efficient radiative cooling agent. Molecular cooling occurs as a thermal instability in many cases with an onset at 2000 to 3500 K, rapidly reducing the temperature by as much as 1000 K. This process may occur in the upper photosphere-lower chromosphere of such stars and can have profound dynamical consequences. The process occurs far from LTE, on a time scale controlled by the reaction rates for SiO formation. SiO masers may be indicative of this process. The molecule CS which may play a similar role in carbon stars and serve as the basis for carbonaceous dust production.

Muchmore, David O.↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage (CRADA Report)

NREL and Element 16 collaborated on sulfur thermal energy storage modeling using NREL’s high performance computing (HPC) resources to assist its application in industrial processes. Industrial process heat (IPH) accounts for ~70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately, 1500 TWht (~60% Terawatt hour thermal) of IPH demand is in the temperature range of 100-300°C. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. This HPC4EI project facilitated Element 16’s development of low-cost and high-impact molten sulfur TES for dispatchable IPH. The development of a high-fidelity model validated by experimental data and HPC simulations enabled the successful resolution of the complex interplay between fluid dynamics and heat transfer processes during transient operation of sulfur TES, overcoming the numerical challenges posed by the non-linear temperature-dependent physical properties of sulfur. The project helped accelerate Element 16’s molten sulfur TES product design and support its broad applications.

25 ENERGY STORAGE↗
NASA NTRS2007

A Return to Innovative Engineering Design, Critical Thinking and Systems Engineering

I believe we are facing a critical time where innovative engineering design is of paramount importance to the success of our aerospace industry. However, the very qualities and attributes necessary for enhancing, educating, and mentoring a creative spirit are in decline in important areas. The importance of creativity and innovation in this country was emphasized by a special edition of the Harvard Business Review OnPoint entitled: "The Creative Company" which compiled a series of past and present articles on the subject of creativity and innovation and stressed its importance to our national economy. There is also a recognition of a lack of engineering, critical thinking and problem-solving skills in our education systems and a trend toward trying to enhance those skills by developing K-12 educational programs such as Project Lead the Way, "Science for All Americans", Benchmarks 2061 , etc. In addition, with respect to spacecraft development, we have a growing need for young to mid-level engineers with appropriate experience and skills in spacecraft design, development, analysis, testing, and systems engineering. As the Director of Engineering at NASA's Johnson Space Center, I realized that sustaining engineering support of an operational human spacecraft such as the Space Shuttle is decidedly different than engineering design and development skills necessary for designing a new spacecraft such as the Crew Exploration Vehicle of the Constellation Program. We learned a very important lesson post Columbia in that the Space Shuttle is truly an experimental and not an operational vehicle and the strict adherence to developed rules and processes and chains of command of an inherently bureaucratic organizational structure will not protect us from a host of known unknowns let alone unknown unknowns. There are no strict rules, processes, or procedures for understanding anomalous results of an experiment, anomalies with an experimental spacecraft like Shuttle, or in the conceptual design of a spacecraft. Engineering design is as much an art as it is a science. The critical thinking skills necessary to uncover lurking problems in an experimental design and creatively develop solutions are some of the same skills necessary to design a new spacecraft. Thus, I believe engineers unfamiliar with or removed from design and development need time to transition and develop the required skill set to be effective spacecraft designers. I believe the creative process necessary in design can be enhanced and even taught as early as grades K-12 and should continue to be nurtured and developed at the university level and beyond. I am going to present a strategy for developing learning teams to address complex multidisciplinary problems and to creatively develop solutions to those problems rapidly at minimal cost. I will frame a real problem, the development of on-orbit thermal protection system repair of the Space Shuttle, and step through the series of skills necessary to enhance the creative process. The case study I will illustrate is based on a real project, the R&D Reinforced Carbon-Carbon (RCC) Repair Team's development of on-orbit repair concepts for damaged Space Shuttle RCC nose cap and/or leading edges.

Camarda, Charles J.↗
DOE OSTI2025

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗
NASA NTRS1978

The solar probe and coronal dynamics

The discovery of coronal holes led to basic changes in ideas about the structure of the low corona and its expansion into the solar wind. The nature of the energy flux is not understood. Current ideas include enhanced thermal conductivities, extended MHD wave heating, and wave momentum transfer, all in rapidly diverging geometries. There is little feel for the relative importance of these processes. The Solar Probe, with its penetration deep into the solar corona, could lead to observational constraints on their relative importance, and thus to an understanding of the origin of the solar wind. Observations from the Solar Probe will also bear on such questions as to whether small scale "intrastream" structure is common close to the Sun in open field-line regions, whether the properties of the wind are pronouncedly different over closed and open field-line regions at five solar radii, and many others. The resolution of these questions requires measurements of the magnetic field and of the proton and electron distribution functions.

Belcher, J.↗