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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Hybrid combustion modeling approach for turbulent jet ignition in natural-gas pre-chamber spark-ignition engines at high EGR

Here, this study presented a hybrid modeling approach for simulating turbulent jet ignition and combustion processes in a natural-gas pre-chamber spark-ignition engine operating under exhaust gas recirculation (EGR) diluted conditions. In-depth analyses of experimental data and simulation results from previous work [Chinnathambi et al., ICEF2021-67836; Kim et al., Fuel 409: 137815, 2026] revealed two key findings: (i) the magnitude of pressure difference between the pre-chamber and main chamber ($∆P_{PC-MC}$) was positively correlated with the combustion duration from the moment of $∆P_{PC-MC}=0$ to the point of 5% mass fraction burned, with larger $∆P_{PC-MC}$ associated with longer duration; and (ii) the turbulent combustion regime in the main chamber transitioned from the broken reaction zone to the corrugated flamelet regime, with the Karlovitz number exceeding 100 immediately after turbulent hot jets were ejected from nozzles, coinciding with observed local extinction events. To accurately simulate the entire combustion process, a hybrid approach was developed under Reynolds-Averaged Navier Stokes framework, combining the G-equation model for pre-chamber combustion with the multi-zone well-stirred reactor approach and a turbulence-chemistry interaction (TCI) submodel for main chamber combustion. The TCI submodel accounted for the attenuation of reaction rates due to turbulent strain and modeled local extinction by suppressing reaction rates under certain flow and flame conditions. When applied to three EGR rate conditions toward the dilution limit, the hybrid modeling approach accurately reproduced experimental data in terms of cylinder pressure, apparent heat release rate, and the observed positive correlation, including the delayed onset of main chamber combustion—a feature not captured by existing combustion models.

computational fluid dynamics simulation↗
NASA NTRS1992

A hybrid electromagnetic-acoustic levitator for the containerless processing of undercooled melts

The hybrid, acoustic-EM levitator discussed provides a small lifting force independently of its EM component by exciting an acoustic resonance that serves as a pressure node at the position of the EM-levitated specimen. The system also stabilizes and damps chaotic oscillations during specimen positioning, and can excite forced oscillations of levitated molten metals for drop-physics and thermophysical property measurements. Attention is given to the character and function of the atmosphere in the levitator. Noncontact temperature measurement is via single-color optical pyrometer.

Hmelo, Anthony B.↗
DOE OSTI2026

Process-level cost analysis of hybrid manufacturing pathways for aerospace structural components

Hybrid manufacturing is a promising route for producing complex aerospace components, yet systematic cost benchmarking across multiple additive-subtractive pathways remains limited. This study presents a comprehensive process-based cost analysis of seven hybrid manufacturing routes, including laser powder bed fusion (L-PBF), powder- and wire-directed energy deposition (DED), wire arc additive manufacturing (WAAM), additive friction stir deposition (AFSD), metal binder jetting (MBJ), and agility forging, followed by scanning and finish machining. Parametric cost models incorporating direct material, labor, and energy costs were developed. L-PBF results are discussed in detail for a pickle fork component and directly compared with commercial pricing. Across all hybrid routes, labor emerged as the dominant cost driver, contributing more than 70% of total manufacturing cost in some cases. AFSD exhibited the lowest cost for aluminum components, with MBJ being its 316 L stainless steel counterpart, after accounting for geometric scaling. Benchmarking against industrial quotes suggests that hybrid manufacturing can achieve cost levels comparable to those of commercial services, although labor-intensive processes exhibit greater deviation. The analysis highlights automation of material handling, setup, and supervision as key opportunities for improving economic competitiveness. Overall, the proposed framework provides a quantitative basis for evaluating and optimizing hybrid manufacturing pathways for aerospace applications.

Baruah, Sweta [ORNL] (ORCID:0009000174256207)↗
DOE OSTI2023

Vision-based localization for cooperative robot-CNC hybrid manufacturing

Wire and arc additive manufacturing (WAAM) has shown promise in recent years for producing large-scale parts with higher deposition rates than other additive processes. WAAM is often combined with subtractive machining to form a hybrid manufacturing process. This hybrid process can be realized by retrofitting computer numerical control (CNC) machines with deposition heads, adding spindles and deposition heads to robots, or developing part localization methods to transfer parts from an additive cell to a CNC machine. Here, a novel, robot-CNC hybrid configuration is introduced where a maneuverable robot is placed in front of a CNC machine to deposit material within the machine envelop. Furthermore, this method removes the need for part localization and the extensive machine modifications required for retrofitting; however, the problem of robot localization is also added. In this work, the effects of error in vision-based, contactless robot localization on machining parameters in a robot-machine hybrid process were studied. Performance was characterized on an implementation of this system using classical computer vision techniques. In addition, machining simulations were conducted to evaluate the effects of image-induced error on chip thickness, material removal rate, and machining allowance. Initial tests show that computer vision could adequately locate a robot for the hybrid WAAM process within .5 mm.

Hybrid manufacturing↗
DOE OSTI2025

Electrochemical Cycling of Liquid Organic Hydrogen Carriers as a Sustainable Approach for Hydrogen Storage and Transportation

Hydrogen (H 2 ), as a high-energy-density molecule, offers a clean solution to carry energy. However, the high diffusivity and low volumetric density of H 2 pose a challenge for long-term storage and transportation. Liquid organic hydrogen carriers (LOHCs) have been suggested as a strategic way to store and transport hydrogen in stable molecules. More so, electrochemical LOHC cycling renders an opportunity to utilize renewable energy for hydrogen storage and transportation toward the goal of eliminating carbon emissions. In this Perspective, examples of electrochemical reactions of organic molecules and their suitability for LOHC couples are examined. A comparative carbon footprint assessment of electrochemical LOHC cycling processes against thermochemical and hybrid LOHC cycling processes was performed. The electrochemical LOHC cycling process had the lowest relative carbon footprint only when highly concentrated LOHCs were used as the feed or when purification of the LOHC product was not required. The carbon footprint in electrochemical cycling of diluted LOHC was primarily contributed to by the LOHC distillation separation process. A sensitivity analysis showed the carbon footprint LOHC concentration dependence during the electrochemical cycling process. Moreover, the electrolyte composition significantly affects the carbon footprint during electrochemical LOHC cycling. Energy utilization, water usage, and toxicity for electrochemical LOHC cycling are discussed to provide an overview for better economic and environmental practices. There are significant opportunities in the electrochemical cycling of LOHCs if appropriate conditions such as high concentrations of reactant, reversible redox cycling ability, high Faradaic efficiencies, and catalyst stabilities are achieved.

25 ENERGY STORAGE↗
NASA NTRS1979

Spectral feature classification and spatial pattern recognition

This paper introduces a spatial pattern recognition processing concept involving the use of spectral feature classification technology and coherent optical correlation. The concept defines a hybrid image processing system incorporating both digital and optical technology. The hybrid instrument provides simplified pseudopattern images as functions of pixel classification from information embedded within a real-scene image. These pseudoimages become simplified inputs to an optical correlator for use in a subsequent pattern identification decision useful in executing landmark pointing, tracking, or navigating functions. Real-time classification is proposed as a research tool for exploring ways to enhance input signal-to-noise ratio as an aid in improving optical correlation. The approach can be explored with developing technology, including a current NASA Langley Research Center technology plan that involves a series of related Shuttle-borne experiments. A first-planned experiment, Feature Identification and Location Experiment (FILE), is undergoing final ground testing, and is scheduled for flight on the NASA Shuttle (STS2/flight OSTA-1) in 1980. FILE will evaluate a technique for autonomously classifying earth features into the four categories: bare land; water; vegetation; and clouds, snow, or ice.

Sivertson, W. E., Jr.↗
NASA NTRS2015

Adapting the SpaceCube v2.0 Data Processing System for Mission-Unique Application Requirements

The SpaceCubeTM v2.0 system is a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. This paper provides an overview of the design architecture, flexibility, and the advantages of the modular SpaceCube v2.0 high performance data processing system for space applications. The current state of the proven SpaceCube technology is based on nine years of engineering and operations. Five systems have been successfully operated in space starting in 2008 with four more to be delivered for launch vehicle integration in 2015. The SpaceCube v2.0 system is also baselined as the avionics solution for five additional flight projects and is always a top consideration as the core avionics for new instruments or spacecraft control. This paper will highlight how this multipurpose system is currently being used to solve design challenges of three independent applications. The SpaceCube hardware adapts to new system requirements by allowing for application-unique interface cards that are utilized by reconfiguring the underlying programmable elements on the core processor card. We will show how this system is being used to improve on a heritage NASA GPS technology, enable a cutting-edge LiDAR instrument, and serve as a typical command and data handling (CDH) computer for a space robotics technology demonstration.

Xilinx FPGA↗
NASA NTRS2015

Adapting the SpaceCube v2.0 Data Processing System for Mission-Unique Application Requirements

The SpaceCube (sup TM) v2.0 system is a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. This paper provides an overview of the design architecture, flexibility, and the advantages of the modular SpaceCube v2.0 high performance data processing system for space applications. The current state of the proven SpaceCube technology is based on nine years of engineering and operations. Five systems have been successfully operated in space starting in 2008 with four more to be delivered for launch vehicle integration in 2015. The SpaceCube v2.0 system is also baselined as the avionics solution for five additional flight projects and is always a top consideration as the core avionics for new instruments or spacecraft control. This paper will highlight how this multipurpose system is currently being used to solve design challenges of three independent applications. The SpaceCube hardware adapts to new system requirements by allowing for application-unique interface cards that are utilized by reconfiguring the underlying programmable elements on the core processor card. We will show how this system is being used to improve on a heritage NASA GPS technology, enable a cutting-edge LiDAR instrument, and serve as a typical command and data handling (C&DH) computer for a space robotics technology demonstration.

SpaceCube↗
NASA NTRS1978

Application of LANDSAT data and digital image processing

The author has identified the following significant results. Based on LANDSAT 1 and 2 data, applications in the fields of coal mining, lignite exploration, and thematic mapping in geology are demonstrated. The hybrid image processing system, its software, and its utilization for educational purposes is described. A pre-operational European satellite is proposed.

Bodechtel, J.↗
DOE OSTI2024

A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing

Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

Engineering↗
DOE OSTI2021

Light Induced Processes in CsPbBr 3 –Au Hybrid Nanocrystals: Electron Transfer and Expulsion of Au

Semiconductor–metal heterostructures such as CsPbBr 3 –Au are useful in photocatalysis. When Au nanoparticles are deposited on the CsPbBr 3 nanocrystal surface, they efficiently quench the photoluminescence of the semiconductor. This process has been studied by femtosecond transient absorption spectroscopy measurements, which indicate that electron transfer to the Au nanoparticles occurs from both hot and relaxed electrons in the conduction band of CsPbBr 3 . The electron transfer rate constant is much larger for the hot electrons compared to the relaxed electrons. Under steady state photoirradiation of CsPbBr 3 –Au heterostructure, the photogenerated electrons from the excited CsPbBr 3 nanocrystals continue to charge the Au nanoparticles. After sufficient irradiation, the gold nanoparticles dissociate from the CsPbBr 3 surface and aggregate into larger size gold nanoparticles. The expulsion of gold nanoparticles restores the original luminescence behavior of CsPbBr 3 nanocrystals. The spectroscopic and morphological studies provide insight into the expulsion of gold nanoparticles in photoirradiated CsPbBr 3 –Au heterostructures.

14 SOLAR ENERGY↗
DOE OSTI2020

Rapid Retooling for Emergency Response with Hybrid Manufacturing

The global manufacturing industry has served as a keystone in supporting the weight of emergency response operations during the coronavirus disease (COVID-19) pandemic. Development of core technologies necessary to prevent the spread of COVID-19, including Personal Protective Equipment, infection testing kits, and vaccine research supplies, requires intensive manufacturing operations to support a population at scale. The production of these items is traditionally dependent on the tool and die industry, requiring imports of steel castings from overseas suppliers. The United States (U.S.) manufacturing industry was left isolated and unprepared as international borders closed overnight and normal supply chains were cut. This technical note provides a forward-looking approach at the benefits of hybrid manufacturing processes to provide rapid reconfiguration capabilities in the U.S. tool and die industry. A demonstration in rapid production of new tooling is provided to illustrate these benefits. Finally, emerging hybrid technologies are discussed in pursuit of more flexible manufacturing operations.

42 ENGINEERING↗
NASA NTRS1972

User oriented multispectral data processing at the University of Michigan

The feasibility of solving practical multispectral data reduction problems by available processing techniques and the identification of areas for more technical development requirements are considered. Parameter mapping and ratio mapping techniques prove their usefulness in a corn blight watch experiment. A hybrid computer processing system is advocated for complete realization of aircraft and spacecraft sensor potentials.

Thomson, F. J.↗
NASA NTRSDate not supplied

Signal and Power Integrity Design Methodology for High-Performance Flight Computing Systems

Computing capabilities of space systems have in-creased onboard performance by orders of magnitude with the use of radiation-tolerant field-programmable gate arrays (FPGA)and processors. The incorporation of signal and power integrity analysis with printed circuit board (PCB) design in reliable computing architectures for space systems has become critical to enable future mission capabilities. Developers launch high-performance processors into a breadth of orbits and missions, running varying applications that create challenges for designing reliable computing hardware. Specifically, for these designs, academic and industry research has focused on component radiation performance, fault mitigation, and reliable architectures. How-ever, other design parameters including electromagnetic interference (EMI), PCB stackup, signal integrity (SI), voltage regulator module (VRM) design, and power distribution network (PDN)are often deprioritized or disregarded as the design matures. Since these characteristics are becoming more significant in high-performance processor designs, this research presents a hardware design and analysis methodology for high-performance, space-computing systems that focuses on a holistic design approach and PDN reliability. While these challenges exist across all space hardware, the reduced PCB dimensions imposed by SmallSats and CubeSats introduce additional hurdles, specifically to VRM and decoupling design. By examining the relationship between the PDN and radiation performance, an analytical relationship is developed that incorporates Total Ionizing Dose and Single-Event Transients to ensure reliability throughout the mission duration. The presented design methodology is applied to the SpaceCube v3.0 Mini, an FPGA-based on-board science data processing system developed at NASA Goddard Space Flight Center.

Advanced avionics↗
NASA NTRS1990

High temperature acoustic and hybrid microwave/acoustic levitators for materials processing

The physical acoustics group at the Jet Propulsion Laboratory developed a single mode acoustic levitator technique for advanced containerless materials processing. The technique was successfully demonstrated in ground based studies to temperatures of about 1000 C in a uniform temperature furnace environment and to temperatures of about 1500 C using laser beams to locally heat the sample. Researchers are evaluating microwaves as a more efficient means than lasers for locally heating a positioned sample. Recent tests of a prototype single mode hybrid microwave/acoustic levitator successfully demonstrated the feasibility of using microwave power as a heating source. The potential advantages of combining acoustic positioning forces and microwave heating for containerless processing investigations are presented in outline form.

Barmatz, Martin↗
DOE OSTI2023

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

42 ENGINEERING↗
NASA NTRS1992

Microwave processing of materials in microgravity

The Jet Propulsion Laboratory is investigating the use of microwave energy as a controlled heating and positioning source for the processing of materials in the microgravity environment of space. Ground-based studies of the positioning capabilities of microwave forces are presented. The ability to quickly and efficiently control the heating of a variety of materials is demonstrated, and the heating of several representative materials is presented. A compact cold-wall microwave furnace compatible with future flight experiments in a shuttle mid-deck cannister is evaluated. The development of a hybrid containerless processing facility that will serve both as an acoustic positioning chamber and a microwave-heating cavity is also proposed. The design characteristics of a cold-wall furnace and hybrid heater/positioner are reviewed.

Barmatz, M.↗