Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “process–structure”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 127 records · Page 7

Organics In Meteorites

The variety of classes of organic compounds that occur in carbonaceous meteorites suggests a rich pre-planetary chemistry with possible connections to interstellar, solar nebular and parent body processes. Structural diversity prevails within all classes examined in detail. Among amino acids for instance, all possible isomers are found up to species containing 4-6 carbon atoms, with abundances decreasing with increasing molecular weight. Such diversity seems limited to those carbonaceous meteorites which show evidence of having been exposed to liquid water; meteorites lacking such evidence also show much lower abundances and less structural diversity in their organic contents. This apparent dependency on water suggests a role for cometary ices in the chemical evolution of organic compounds on parent bodies. Measurements of the stable isotope compositions of C, H, N and S in classes of compounds and at the individual compound level show strong deviations from average chondritic values. These deviations are difficult to explain by solar system or parent body processes, and precedents for some of these isotopic anomalies exist in interstellar (e.g., high D/H ratios) and circumstellar chemistry. Therefore, presolar origins for much if not all of the meteoritic organic compounds (or their precursors) is a distinct possibility. In contrast, evidence of solar nebular origins is either lacking or suspect. Results from molecular and isotopic analyses of meteoritic organics, from laboratory simulations and from a model of interstellar grain reactions will be used to flesh out the hypothesis that this material originated with interstellar chemistry, was distributed within the early solar system as cometary ices, and was subsequently altered on meteorite parent bodies to yield the observed compounds.

Chang, Sherwood↗

Evaluation of Graphite Fiber/Polyimide PMCs from Hot Melt versus Solution Prepreg

Carbon fiber reinforced high temperature polymer matrix composites (PMC) have been extensively investigated as potential weight reduction replacements of various metallic components in next generation high performance propulsion rocket engines. The initial phase involves development of comprehensive composite material-process-structure-design-property in-service performance correlations and database, especially for a high stiffness facesheet of various sandwich structures. Overview of the program plan, technical approaches and current multi-team efforts will be presented. During composite fabrication, it was found that the two large volume commercial prepregging methods (hot-melt vs. solution) resulted in considerably different composite cure behavior. Details of the process-induced physical and chemical modifications in the prepregs, their effects on composite processing, and systematic cure cycle optimization studies will be discussed. The combined effects of prepregging method and cure cycle modification on composite properties and isothermal aging performance were also evaluated.

Shin, Eugene E.↗

NASA Workshop on Technology for Human Robotic Exploration and Development of Space

Continued constrained budgets and growing interests in the industrialization and development of space requires NASA to seize every opportunity for assuring the maximum return on space infrastructure investments. This workshop provided an excellent forum for reviewing, evaluating, and updating pertinent strategic planning, identifying advanced concepts and high-risk/high-leverage research and technology requirements, developing strategies and roadmaps, and establishing approaches, methodologies, modeling, and tools for facilitating the commercial development of space and supporting diverse exploration and scientific missions. Also, the workshop addressed important topic areas including revolutionary space systems requiring investments in innovative advanced technologies; achieving transformational space operations through the insertion of new technologies; revolutionary science in space through advanced systems and new technologies enabling experiments to go anytime to any location; and, innovative and ambitious concepts and approaches essential for promoting advancements in space transportation. Details concerning the workshop process, structure, and results are contained in the ensuing report.

Mankins, J. C.↗

A VHDL Core for Intrinsic Evolution of Discrete Time Filters with Signal Feedback

The design of an Evolvable Machine VHDL Core is presented, representing a discrete-time processing structure capable of supporting control system applications. This VHDL Core is implemented in an FPGA and is interfaced with an evolutionary algorithm implemented in firmware on a Digital Signal Processor (DSP) to create an evolvable system platform. The salient features of this architecture are presented. The capability to implement IIR filter structures is presented along with the results of the intrinsic evolution of a filter. The robustness of the evolved filter design is tested and its unique characteristics are described.

Gwaltney, David A.↗

Evaluation of Graphite Fiber/Polyimide PMCs from Hot Melt vs Solution Prepreg

Carbon fiber reinforced high temperature polymer matrix composites (PMC) have been extensively investigated as potential weight reduction replacements of various metallic components in next generation high performance propulsion rocket engines. The initial phase involves development of comprehensive composite material-process-structure-design-property-in-service performance correlations and database, especially for a high stiffness facesheet of various sandwich structures. Overview of the program plan, technical approaches and current multi-team efforts will be presented. During composite fabrication, it was found that the two large volume commercial prepregging methods (hot-melt vs. solution) resulted in considerably different composite cure behavior. Details of the process-induced physical and chemical modifications in the prepregs, their effects on composite processing, and systematic cure cycle optimization studies will be discussed. The combined effects of prepregging method and cure cycle modification on composite properties and isothermal aging performance were also evaluated.

Shin, E. Eugene↗

Social Semantics for an Effective Enterprise

An evolution of the Semantic Web, the Social Semantic Web (s2w), facilitates knowledge sharing with "useful information based on human contributions, which gets better as more people participate." The s2w reaches beyond the search box to move us from a collection of hyperlinked facts, to meaningful, real time context. When focused through the lens of Enterprise Search, the Social Semantic Web facilitates the fluid transition of meaningful business information from the source to the user. It is the confluence of human thought and computer processing structured with the iterative application of taxonomies, folksonomies, ontologies, and metadata schemas. The importance and nuances of human interaction are often deemphasized when focusing on automatic generation of semantic markup, which results in dissatisfied users and unrealized return on investment. Users consistently qualify the value of information sets through the act of selection, making them the de facto stakeholders of the Social Semantic Web. Employers are the ultimate beneficiaries of s2w utilization with a better informed, more decisive workforce; one not achieved with an IT miracle technology, but by improved human-computer interactions. Johnson Space Center Taxonomist Sarah Berndt and Mike Doane, principal owner of Term Management, LLC discuss the planning, development, and maintenance stages for components of a semantic system while emphasizing the necessity of a Social Semantic Web for the Enterprise. Identification of risks and variables associated with layering the successful implementation of a semantic system are also modeled.

Berndt, Sarah↗

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The United States Space Operational Space Shuttle Fleet Consists of three shuttles with an average age of 19.7 years. Shuttles are exposed to corrosive conditions while undergoing final closeout for missions at the launch pad and extreme conditions during ascent, orbit, and descent that may accelerate the corrosion process. Structural corrosion under TPS could progress undetected (without tile removal) and eventually result in reduction in structural capability sufficient to create negative margins of . safety and ultimate loss of local structural capability.

Kammerer, Catherine C.↗

Advanced Near Net Shape Technology

The objective of the Advanced Near Net Shape Technology (ANNST) project is to radically improve near net shape manufacturing methods from the current Technology/ Manufacturing Readiness Levels (TRL/MRL 3-4) to the point where they are viable candidates (TRL/ MRL-6) for shortening the time and cost for insertion of new aluminum alloys and revolutionary manufacturing methods into the development/improvement of space structures. Conventional cyrotank manufacturing processes require fabrication of multiple pieces welded together to form a complete tank. A variety of near net shape manufacturing processes has demonstrated excellent potential for enabling single-piece construction of components such as domes, barrels, and ring frames. Utilization of such processes can dramatically reduce the extent of welding and joining needed to construct cryogenic tanks and other aerospace structures. The specific focus of this project is to successfully mature the integrally stiffened cylinder (ISC) process in which a single-piece cylinder with integral stiffeners is formed in one spin/flow forming process. Structural launch vehicle components, like cryogenic fuel tanks (e.g., space shuttle external tank), are currently fabricated via multipiece assembly of parts produced through subtractive manufacturing techniques. Stiffened structural panels are heavily machined from thick plate, which results in excessive scrap rates. Multipiece construction requires welds to assemble the structure, which increases the risk for defects and catastrophic failures.

Vickers, John↗

TPSAS-NF1676L-32709-DND

Outline - Process-Structure-Performance Framework - Process-Specific Defects in selective laser melting (SLM) additive manufacturing (AM) process - Idealized Keyhole/Entrapped gas pores - Idealized Lack of Fusion (LoF) pores - Influence of Pore Geometry on Strain Localization - 3D Model of LoF pores - Partial validation of the 3D LoF 2 model

Saikumar R Yeratapally↗

An Uncertainty Quantification Framework for Autonomous Flight System Tracking and Health Monitoring

This work proposes a perspective towards establishing a framework for uncertainty quantification of autonomous system tracking and health monitoring. The approach leverages the use of a predictive process structure, which maps uncertainty sources and their interaction according to the quantity of interest and the goal of the predictive estimation. It is systematic and uses basic elements that are system agnostic, and therefore needs to be tailored according to the specificity of the application. This work is motivated by the interest in low-altitude unmanned aerial vehicle operations, where awareness of vehicle and airspace state becomes more relevant as the density of autonomous operations grows rapidly. Predicted scenarios in the area of small vehicle operations and urban air mobility have no precedent, and holistic frameworks to perform prognostics and health management (PHM) at the system- and airspace-level are missing formal approaches to account for uncertainty. At the end of the paper, two case studies demonstrate implementation framework of trajectory tracking and health diagnosis for a small unmanned aerial vehicle. This work has been accepted for publication at the International Journal of Prognostics and Health Management Jan 2021. Minor edits have been incorporated to this original submission to incorporate complete overview and software integration.

Uncertainty Quantification↗

Integrated Computational Materials Engineering (ICME) Capability Maturity Levels for Ecosystems Enabling Digital Transformation

Digital engineering (DE) and integrated computational materials engineering (ICME) are widely recognized as critical enablers of faster, more affordable, and more reliable aerospace systems. However, many organizations have struggled to realize the promised return on investment (ROI) from digital initiatives. A primary reason is the absence of a shared, decision-focused framework that distinguishes simple digitization of existing workflows from true digital transformation that fundamentally changes how engineering decisions are made. This paper introduces an ICME capability maturity framework that fills this gap. The framework defines six cumulative ICME capability maturity levels (CMLs), explicitly tied to decision authority, engineering integration, optimization, and uncertainty management across material, process, structure, and performance scales. It is designed to complement established readiness metrics such as technology readiness levels (TRLs), manufacturing readiness levels (MRLs), and integration readiness levels (IRLs), by addressing a missing dimension: the conditions required for model-informed decision authority across scales. A unifying figure and capability table illustrate the six-level ICME Capability Maturity Framework, showing how organizations progress from digitization—with limited or negative ROI—to true digital transformation, where ICME-enabled workflows deliver measurable improvements in decision quality, cycle time, risk reduction, and reuse. The framework is intended for both technical practitioners and executive leadership, providing a common language to assess current state, guide roadmaps, align software ecosystem investments, and set realistic expectations for digital transformation outcomes. A regulatory-relevant statement clarifying the relationship between ICME capability and existing certification frameworks is provided.

ICME↗

NASA BPS Reduced Gravity Integrated Computational Materials Engineering (ICME) Study

The Biological and Physical Sciences (BPS) Division of NASA’s Science Mission Directorate (SMD), and its predecessors, has sponsored extensive flight and ground experiments yielding benchmark datasets in many materials science research areas including thermophysical properties and solidification microstructure formation and evolution. The subject study sought to motivate and focus BPS’s engagement within the broader Integrated ICME community to understand the phenomena underlying material processing, structure, and properties in the microgravity environment of space and to support future space exploration efforts.

Louise Littles↗

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗

Interpretation of wide-angle x-ray diffraction patterns from mesophase pitch-based carbon fibers – a simulation and experimental study

Carbon fiber is a critical material in a wide range of industries, where it is highly valued for its high specific strength/stiffness, excellent wear resistance, efficient electrical and thermal transport properties, chemical resistance, and low coefficient of thermal expansion. The properties of a specific carbon fiber are closely tied to its structural characteristics at all length scales. Here, in this work, we applied wide-angle x-ray diffraction to a set of heat-treated mesophase pitch-based carbon fibers, with the goal of elucidating the crystalline structures as a function of fiber orientation. To assist with analysis and interpretation of the experimental data, we employed diffraction pattern simulations using the scalar and vector forms of the Debye scattering equation to determine the influence of basal plane orientation, crystalline ordering (turbostratic-graphitic), and basal plane asymmetry on the diffraction patterns. The results presented here suggest that growth of the transverse crystallites in mesophase pitch-based carbon fiber is fixed until graphitization temperatures are reached. The work completed here provides a framework for the analysis of carbon fiber and other oriented carbon-based materials via diffraction.

36 MATERIALS SCIENCE↗

Additive manufacturing of metal matrix composites

Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

36 - MATERIALS SCIENCE↗

Embedded Sensing in Additive Manufacturing Metal and Polymer Parts: A Comparative Study of Integration Techniques and Structural Health Monitoring Performance

This study presents a comparative evaluation of post-process sensor integration in additively manufactured (AM) metal and the in-situ process for polymer structures for structural health monitoring (SHM), with an emphasis on embedded sensors. Geometrically identical specimens were fabricated using copper via metal fused filament fabrication (FFF) and PLA via polymer FFF, with piezoelectric transducers (PZTs) inserted into internal cavities to assess the influence of material and placement on sensing fidelity. Mechanical testing under compressive and point loads generated signals that were transformed into time–frequency spectrograms using a Short-Time Fourier Transform (STFT) framework. An engineered RGB representation was developed, combining global amplitude scaling with an amplitude-envelope encoding to enhance contrast and highlight subtle wave features. These spectrograms served as inputs to convolutional neural networks (CNNs) for classification of load conditions and detection of damage-related features. Results showed reliable recognition in both copper and PLA specimens, with CNN classification accuracies exceeding 95%. Embedded PZTs were especially effective in PLA, where signal damping and environmental sensitivity often hinder surface-mounted sensors. This work demonstrates the advantages of embedded sensing in AM structures, particularly when paired with spectrogram-based feature engineering and CNN modeling, advancing real-time SHM for aerospace, energy, and defense applications.

additive manufacturing↗