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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Critical statistical assessment of data in metal additive manufacturing

Obtaining high quality data reflecting the relationships between the additive manufacturing (AM) process parameters, material microstructure and mechanical properties is crucial for the use of machine learning in AM. A database of over 4,000 data entries of metal AM was created thanks to a large number of literature studies on key process parameters and indicators of build quality. Meta-analysis reveals critical biases in the literature. Firstly, majority of studies report only high quality builds, these imbalances in reporting result in weak correlation between process parameters, properties and consolidation, limiting the ability of machine learning models to generalize beyond optimized conditions. Nevertheless, the trained models accurately predict yield strength ($R^2 = 0.85$), suggesting that certain process–property relationships are effectively captured within these models. Secondly, quantitative microstructural data are largely absent, limiting the learning of the microstructure-mechanical properties relationships. Finally, current process window identification is based largely on the consolidation, despite significant uncertainty in its measurement. It is important to identify the process map on the basis of not only the consolidation, but also mechanical behaviour under loading. Such a identification shows that 316 L and Inconel have much larger process map (i.e. highly printable) in comparison to the AlSi10Mg and Ti6Al4V.

Additive manufacturing↗

NASA NTRS1992

Minimizing distortion in truss structures - A Hopfield network solution

Distortions in truss structures can result from random errors in element lengths that are typical of a manufacturing process. These distortions may be minimized by an optimal selection of elements from those available for placement between the prescribed nodes - a combinatorial optimization problem requiring significant investment of computational resource for all but the smallest problems. The present paper describes a formulation in which near-optimal element assignments are obtained as minimum-energy stable states, of an analogous Hopfield neural network. This requires mapping of the optimization problem into an energy function of the appropriate Liapunov form. The computational architecture is ideally suited to a parallel processor implementation and offers significant savings in computational effort. A numerical implementation of the approach is discussed with reference to planar truss problems.

Fu, B.↗

NASA NTRS2007

Optimisation of the Future Routine Orbit for Mars Express

Mars Express (MEX), the first planetary mission of the European Space Agency (ESA), reached Mars on December 25th 2003. Since then it is performing routine operations. Its operational phase had to cover one Martian year, with the possibility of an extension for a second Martian year (i.e. until November 2007). The end of the mission extension is approaching but, given the good health of the payload instruments and the high science return of the mission, there is a strong will to achieve further extensions. Mars Express is also seen as an important asset, capable to provide relay functions for future Martian missions. The ESA Science Program Committee has recently approved a second extension of the MEX mission until May 2009 and even further extensions are possible. Mars Express has an eccentric quasi-polar orbit with a period of approximately 6.72 hours and a pericentre height of about 300 km. Science observations are mainly performed at pericentre (but not only). In addition the orbit has a resonance of 11 revolutions per 3 Martian days. This means that ground tracks corresponding to orbits separated by 11 revolutions are adjacent, such that a given area can be covered by the on-board camera without leaving gaps. The J2 effect of Mars causes a drift of both ascending node and argument of pericentre. The drift of argument of pericentre makes it possible to observe periodically all Mars latitudes from close distance. Illumination conditions at pericentre are influenced by both the drift of the argument of pericentre and the drift of ascending node, as well as by the rotation of Mars around the Sun. The original MEX routine orbit was optimized for the duration of the nominal mission and extension, such that it produced a balanced share of day-side observations (for the optical instruments) and night-side observations (for the radar). The orbit was thus not optimized for the time beyond the assumed extension. Indeed, the evolution of the ascending node and argument of pericentre would cause in the following years a drift of the pericentre towards night-side observation conditions, hence uninteresting for the optical instruments. In order to prevent this an optimisation process for the future routine orbit has taken place. The share between day-side and night-side observations can be controlled by adjusting the drift of argument of pericentre and ascending node. This can in particular be achieved by changing the semimajor axis, eccentricity and/or inclination. A change of inclination is inefficient compared to a change in semimajor axis and eccentricity, and has therefore been discarded. An in-plane maneuvre can be performed to change both semi-major axis and eccentricity, and thus the period of the orbit. Although an apocentre manoeuvre is cheaper in terms of deltaV, it would result in raising the pericentre height, which is unfavourable for close observations. Hence a pericentre manoeuvre is proposed, which will increase the apocentre height. A repeat cycle is still required to allow mapping areas with adjacent ground tracks, so the change of semimajor axis must result in a new resonance. Resonances 18:5, 25:7 and 7:2 have been considered as potential candidates. The resulting long term evolution of the observation conditions has been analysed. Finally it has been decided to perform a change of orbit to reach the 18:5. Another aspect of the optimisation process is the control of the ground track. The previous MEX reference trajectory included regular maneuvres at every apocentre in order to adjust the orbital period, such that the separation of the ground tracks would be optimal, regardless of the latitude of pericentre. The implementation of the actual delatVs on-board was done partly by optimizing the attitude of reaction-wheel desaturation activities. Despite of it, this strategy has a significant propellant cost, because it prevents to optimize reaction wheel de-saturation activities to minimize propellant consumption. Therore, with the aim at preserving propellant resources for a long time extension it has been agreed to stop the ground-track control. This requires now a more accurate science operation planning, with improved attitude pointing control. Finally, the approach to phase Mars Express to provide back-up relay functions for NASA Phoenix landing is explained. In the context of the routine trajectory optimisation a new requirement for close fly-bys at Phobos, with different observation geometries, has been specified. The approach to fulfill this requirement is explained.

Carranza, Manuel↗

DOE OSTI2026

Extremized nonlinear and linearized responses in soft metamaterials enabled by gradient-based design and grayscale digital light processing

In this study, we develop a gradient-based design approach that exploits grayscale digital light processing (DLP) 3D printing for extremizing the nonlinear and linearized response of soft metamaterials — materials that harness engineered geometric instabilities to undergo large and programmable changes in configuration. Grayscale DLP approaches modulate local mechanical properties at the pixel scale by tuning the light intensity within a single grayscale image, unlocking an exceptionally large design space. To effectively navigate this space, we develop smooth mappings between local light intensity values and global quantities of interest that characterize the behavior of soft metamaterials. Enabling these smooth mappings are robust and differentiable nonlinear finite element simulations powered by a trust region solver. A PDE-constrained optimization problem is then solved to invert these mappings and produce light intensity distributions that endow the printed part with varying stiffness and flexibility in distinctive regions. It is shown that optimizing the distribution of soft and stiff phases throughout a metamaterial structure results in markedly different buckling and self-contact configurations to drive extremized nonlinear compression and linearized vibration responses. Optimized light intensity distributions are translated to grayscale images and directly used to print soft metamaterial samples, showing remarkable agreement between the buckling and self-contact response in simulated and measured deformed configurations.

Additive manufacturing↗

NASA NTRS2005

X-Ray Spectroscopy of Optically Bright Planets using the Chandra Observatory

Since its launch in July 1999, Chandra's Advanced CCD Imaging Spectrometer (ACIS) has observed several planets (Venus, Mars, Jupiter and Saturn) and 6 comets. At 0.5 arc-second spatial resolution, ACIS detects individual x-ray photons with good quantum efficiency (25% at 0.6 KeV) and energy resolution (20% FWHM at 0.6 KeV). However, the ACIS CCDs are also sensitive to optical and near-infrared light, which is absorbed by optical blocking filters (OBFs) that eliminate optical contamination from all but the brightest extended sources, e.g., planets. .Jupiter at opposition subseconds approx.45 arc-seconds (90 CCD pixels.) Since Chandra is incapable of tracking a moving target, the planet takes 10 - 20 kiloseconds to move across the most sensitive ACIS CCD, after which the observatory must be re-pointed. Meanwhile, the OBF covering that CCD adds an opt,ical signal equivalent to approx.110 eV to each pixel that lies within thc outline of the Jovian disk. This has three consequences: (1) the observatory must be pointed away from Jupiter while CCD bias maps are constructed; (2) most x-rays from within the optical image will be misidentified as charged-particle background and ignored; and (3) those x-rays that are reported will bc assigned anomalously high energies. The same also applies to thc other planets, but is less serious since they are either dimmer at optical wavelengths, or they show less apparent motion across the sky, permitting reduced CCD exposure times: the optical contamination from Saturn acids approx.15 eV per pixel, and from Mars and Venus approx.31 eV. After analyzing a series of short .Jupiter observations in December 2000, ACIS parameters were optimized for the February 2003 opposition. CCD bias maps were constructed while Chandra pointed away from Jupiter, and the subsequent observations employed on-board software to ignore any pixel that contained less charge than that expected from optical leakage. In addition, ACIS was commanded to report 5 x 5 arrays of pixel values surrounding each x-ray event, and the outlying values were employed during ground processing to correct for the optical contamination.

Ford, P. G.↗

NASA NTRS1996

Development of Software to Model AXAF-I Image Quality

This draft final report describes the work performed under the delivery order number 145 from May 1995 through August 1996. The scope of work included a number of software development tasks for the performance modeling of AXAF-I. A number of new capabilities and functions have been added to the GT software, which is the command mode version of the GRAZTRACE software, originally developed by MSFC. A structural data interface has been developed for the EAL (old SPAR) finite element analysis FEA program, which is being used by MSFC Structural Analysis group for the analysis of AXAF-I. This interface utility can read the structural deformation file from the EAL and other finite element analysis programs such as NASTRAN and COSMOS/M, and convert the data to a suitable format that can be used for the deformation ray-tracing to predict the image quality for a distorted mirror. There is a provision in this utility to expand the data from finite element models assuming 180 degrees symmetry. This utility has been used to predict image characteristics for the AXAF-I HRMA, when subjected to gravity effects in the horizontal x-ray ground test configuration. The development of the metrology data processing interface software has also been completed. It can read the HDOS FITS format surface map files, manipulate and filter the metrology data, and produce a deformation file, which can be used by GT for ray tracing for the mirror surface figure errors. This utility has been used to determine the optimum alignment (axial spacing and clocking) for the four pairs of AXAF-I mirrors. Based on this optimized alignment, the geometric images and effective focal lengths for the as built mirrors were predicted to cross check the results obtained by Kodak.

Ahmad, Anees↗

NASA NTRS2021

Achieving Breakthroughs in Global Hydrologic Science by Unlocking the Power of Multisensor, Multidisciplinary Earth Observations

Over the last half century, remote sensing has transformed hydrologic science. Whereas early efforts were devoted to observation of discrete variables, we now consider spaceborne missions dedicated to interlinked global hydrologic processes.Furthermore, cloud computing and computational techniquesare accelerating analyses of these data. How will the hydrologic community use these new resources to better understand the world’s water and relatedchallenges facing society? In this Commentary, we suggest that optimizing the benefits of remote sensing for advancing hydrologic research will happen byintegratingmultidisciplinary and multisensor data, leveraging commercial satellite measurements, and employingdata assimilation, cloud computing, and machine learning.We provide several recommendations to these ends. Plain Language Summary Observations from satellites have transformed hydrologic science. Early efforts, five decades ago, mapped attributes like snow cover, rainfall, topography, and vegetation, but now we consider new missions specifically designed to study global hydrologic processes. We also take advantageof new technologies like cloud computing and artificial intelligence. We describe strategiesfor maximizing the benefits of remote sensing for hydrology, encouraging research across disciplines using multiple sensors, using new commercially available satellites, and combining remote sensing measurements with hydrologic models.

Michael Durand↗

NASA NTRS2004

Autonomous In-Situ Resources Prospector

This presentation will describe the concept of an autonomous, intelligent, rover-based rapid surveying system to identify and map several key lunar resources to optimize their ISRU (In Situ Resource Utilization) extraction potential. Prior to an extraction phase for any target resource, ground-based surveys are needed to provide confirmation of remote observation, to quantify and map their 3-D distribution, and to locate optimal extraction sites (e.g. ore bodies) with precision to maximize their economic benefit. The system will search for and quantify optimal minerals for oxygen production feedstock, water ice, and high glass-content regolith that can be used for building materials. These are targeted because of their utility and because they are, or are likely to be, variable in quantity over spatial scales accessible to a rover (i.e., few km). Oxygen has benefits for life support systems and as an oxidizer for propellants. Water is a key resource for sustainable exploration, with utility for life support, propellants, and other industrial processes. High glass-content regolith has utility as a feedstock for building materials as it readily sinters upon heating into a cohesive matrix more readily than other regolith materials or crystalline basalts. Lunar glasses are also a potential feedstock for oxygen production, as many are rich in iron and titanium oxides that are optimal for oxygen extraction. To accomplish this task, a system of sensors and decision-making algorithms for an autonomous prospecting rover is described. One set of sensors will be located in the wheel tread of the robotic search vehicle providing contact sensor data on regolith composition. Another set of instruments will be housed on the platform of the rover, including VIS-NIR imagers and spectrometers, both for far-field context and near-field characterization of the regolith in the immediate vicinity of the rover. Also included in the sensor suite are a neutron spectrometer, ground-penetrating radar, and an instrumented cone penetrometer for subsurface assessment. Output from these sensors will be evaluated autonomously in real-time by decision-making software to evaluate if any of the targeted resources has been detected, and if so, to quantify their abundance. Algorithms for optimizing the mapping strategy based on target resource abundance and distribution are also included in the autonomous software. This approach emphasizes on-the-fly survey measurements to enable efficient and rapid prospecting of large areas, which will improve the economics of ISRU system approaches. The mature technology will enable autonomous rovers to create in-situ resource maps of lunar or other planetary surfaces, which will facilitate human and robotic exploration.

Dissly, R. W.↗

NASA NTRS1983

Study of LANDSAT-D thematic mapper performance as applied to hydrocarbon exploration

Improved delineation of known oil and gas fields in southern Ontario and a spectacularly high amount of structural information on the Owl Creek, Wyoming scene were obtained from analysis of TM data. The use of hue, saturation, and value image processing techniques on a Death Valley, California scene permitted direct comparison of TM processed imagery with existing 1:250,000 scale geological maps of the area and revealed small outcrops of Tertiary volcanic material overlying Paleozoic sections. Analysis of TM data over Lawton, Oklahoma suggests that the reducing chemical environment associated with hydrocarbon seepage change ferric iron to soluble ferrous iron, allowing it to be leached. Results of the band selection algorithm show a suprising consistency, with the 1,4,5 combination selected as optimal in most cases.

Everett, J. R.↗

NASA NTRS2004

Integrated Modeling Activities for the James Webb Space Telescope: Structural-Thermal-Optical Analysis

The James Web Space Telescope (JWST) is a large, infrared-optimized space telescope scheduled for launch in 2011. This is a continuation of a series of papers on modeling activities for JWST. The structural-thermal-optical, often referred to as STOP, analysis process is used to predict the effect of thermal distortion on optical performance. The benchmark STOP analysis for JWST assesses the effect of an observatory slew on wavefront error. Temperatures predicted using geometric and thermal math models are mapped to a structural finite element model in order to predict thermally induced deformations. Motions and deformations at optical surfaces are then input to optical models, and optical performance is predicted using either an optical ray trace or a linear optical analysis tool. In addition to baseline performance predictions, a process for performing sensitivity studies to assess modeling uncertainties is described.

Johnston, John D.↗

DOE OSTI2026

Solar Thermal Energy Planner (STEP 1): A New Decision Support Tool for Solar Industrial Process Heat Applications

Solar thermal technologies are a promising technology to supply low-cost thermal energy to industrial processes, but there are often significant barriers to entry to industrial owners considering these technologies for their energy demands. To overcome this barrier and convey economic value to customers, NREL and Sandia National Laboratories developed Solar Thermal Energy Planner (STEP 1), a new web-based decision support tool for solar industrial process heat systems. At SolarPACES 2024, the STEP 1 tool was still under development; progress, methodologies, and a preliminary case study was presented. With the STEP 1 tool launch in May 2025, in this work, the initial version of the full public tool will be presented with demonstrations of its capabilities using a few case studies. First, the user's process heat needs such as location, process media (e.g., steam, air), process temperature, land availability, electricity and fuel costs, among other parameters. STEP 1 features a mapping interface that allows users to draw land and roof boundaries. The process media and temperature inform technology selection criteria modules that determine the appropriate solar thermal collection technologies, as well as congruent heat transfer media (e.g., hot water, oil, salt). Once the solar thermal technology selected, its nominal thermal production for the given site is characterized using NREL's System Advisor Model (SAM). Then, a modified version of NREL's REopt optimal sizing and dispatch optimization tool determines cost-optimal sizing. Within minutes, the user receives the results of the technoeconomics analysis, including the size and performance of the cost-optimal solar-plus-storage system. The cost of the system is compared to business-as-usual (e.g., an existing, standalone natural gas boiler). Users can download key results to store for sensitivity analyses. Examples of flat plate collector, parabolic trough, and molten salt tower applications with and without PV hybridization for different industrial facility types are presented in this work. The STEP 1 tool aims to reduce barriers to the adoption of solar heating solutions stemming from a lack of familiarity and technical background with solar system design options and costs among industry stakeholders.

14 SOLAR ENERGY↗

NASA NTRS1987

Problem size, parallel architecture and optimal speedup

The communication and synchronization overhead inherent in parallel processing can lead to situations where adding processors to the solution method actually increases execution time. Problem type, problem size, and architecture type all affect the optimal number of processors to employ. The numerical solution of an elliptic partial differential equation is examined in order to study the relationship between problem size and architecture. The equation's domain is discretized into n sup 2 grid points which are divided into partitions and mapped onto the individual processor memories. The relationships between grid size, stencil type, partitioning strategy, processor execution time, and communication network type are analytically quantified. In so doing, the optimal number of processors was determined to assign to the solution, and identified (1) the smallest grid size which fully benefits from using all available processors, (2) the leverage on performance given by increasing processor speed or communication network speed, and (3) the suitability of various architectures for large numerical problems.

Nicol, David M.↗

NASA NTRS1988

Problem size, parallel architecture, and optimal speedup

Nicol, David M.↗

NASA NTRS1993

A comparison of multiprocessor scheduling methods for iterative data flow architectures

A comparative study is made between the Algorithm to Architecture Mapping Model (ATAMM) and three other related multiprocessing models from the published literature. The primary focus of all four models is the non-preemptive scheduling of large-grain iterative data flow graphs as required in real-time systems, control applications, signal processing, and pipelined computations. Important characteristics of the models such as injection control, dynamic assignment, multiple node instantiations, static optimum unfolding, range-chart guided scheduling, and mathematical optimization are identified. The models from the literature are compared with the ATAMM for performance, scheduling methods, memory requirements, and complexity of scheduling and design procedures.

Storch, Matthew↗

NASA NTRS2010

HYTHIRM Radiance Modeling and Image Analyses in Support of STS-119, STS-125 and STS-128 Space Shuttle Hypersonic Re-entries

We provide the first geometrically accurate (i.e., 3-D) temperature maps of the entire windward surface of the Space Shuttle during hypersonic reentry. To accomplish this task we began with estimated surface temperatures derived from CFD models at integral high Mach numbers and used them, the Shuttle's surface properties and reasonable estimates of the sensor-to-target geometry to predict the emitted spectral radiance from the surface (in units of W sr-1 m-2 nm-1). These data were converted to sensor counts using properties of the sensor (e.g. aperture, spectral band, and various efficiencies), the expected background, and the atmosphere transmission to inform the optimal settings for the near-infrared and midwave IR cameras on the Cast Glance aircraft. Once these data were collected, calibrated, edited, registered and co-added we formed both 2-D maps of the scene in the above units and 3-D maps of the bottom surface in temperature that could be compared with not only the initial inputs but also thermocouple data from the Shuttle itself. The 3-D temperature mapping process was based on the initial radiance modeling process. Here temperatures were guessed for each node in a well-resolved 3-D framework, a radiance model was produced and compared to the processed imagery, and corrections to the temperature were estimated until the iterative process converged. This process did very well in characterizing the temperature structure of the large asymmetric boundary layer transition the covered much of the starboard bottom surface of STS-119 Discovery. Both internally estimated accuracies and differences with CFD models and thermocouple measurements are at most a few percent. The technique did less well characterizing the temperature structure of the turbulent wedge behind the trip due to limitations in understanding the true sensor resolution. (Note: Those less inclined to read the entire paper are encouraged to read an Executive Summary provided at the end.)

Gibson, David M.↗

DOE OSTI2024

A Deep Learning-Driven Sampling Technique to Explore the Phase Space of an RNA Stem-Loop

The folding and unfolding of RNA stem-loops are critical biological processes; however, their computational studies are often hampered by the ruggedness of their folding landscape, necessitating long simulation times at the atomistic scale. Here, we adapted DeepDriveMD (DDMD), an advanced deep learning-driven sampling technique originally developed for protein folding, to address the challenges of RNA stem-loop folding. Although tempering- and order parameter-based techniques are commonly used for similar rare-event problems, the computational costs or the need for a priori knowledge about the system often present a challenge in their effective use. DDMD overcomes these challenges by adaptively learning from an ensemble of running MD simulations using generic contact maps as the raw input. DeepDriveMD enables on-the-fly learning of a low-dimensional latent representation and guides the simulation toward the undersampled regions while optimizing the resources to explore the relevant parts of the phase space. We showed that DDMD estimates the free energy landscape of the RNA stem-loop reasonably well at room temperature. Our simulation framework runs at a constant temperature without external biasing potential, hence preserving the information on transition rates, with a computational cost much lower than that of the simulations performed with external biasing potentials. Here, we also introduced a reweighting strategy for obtaining unbiased free energy surfaces and presented a qualitative analysis of the latent space. This analysis showed that the latent space captures the relevant slow degrees of freedom for the RNA folding problem of interest. Finally, throughout the manuscript, we outlined how different parameters are selected and optimized to adapt DDMD for this system. We believe this compendium of decision-making processes will help new users adapt this technique for the rare-event sampling problems of their interest.

Gupta, Ayush↗

NASA NTRS1991

A parallel-pipelined architecture for a multi carrier demodulator

Analog devices have been used for processing the information on board the satellites. Presently, digital devices are being used because they are economical and flexible as compared to their analog counterparts. Several schemes of digital transmission can be used depending on the data rate requirement of the user. An economical scheme of transmission for small earth stations uses single channel per carrier/frequency division multiple access (SCPC/FDMA) on the uplink and time division multiplexing (TDM) on the downlink. This is a typical communication service offered to low data rate users in commercial mass market. These channels usually pertain to either voice or data transmission. An efficient digital demodulator architecture is provided for a large number of law data rate users. A demodulator primarily consists of carrier, clock, and data recovery modules. This design uses principles of parallel processing, pipelining, and time sharing schemes to process large numbers of voice or data channels. It maintains the optimum throughput which is derived from the designed architecture and from the use of high speed components. The design is optimized for reduced power and area requirements. This is essential for satellite applications. The design is also flexible in processing a group of a varying number of channels. The algorithms that are used are verified by the use of a computer aided software engineering (CASE) tool called the Block Oriented System Simulator. The data flow, control circuitry, and interface of the hardware design is simulated in C language. Also, a multiprocessor approach is provided to map, model, and simulate the demodulation algorithms mainly from a speed view point. A hypercude based architecture implementation is provided for such a scheme of operation. The hypercube structure and the demodulation models on hypercubes are simulated in Ada.

Kwatra, S. C.↗

DOE OSTI2026

A New Route Toward Atomically Flat and Defect-Free Ge/SiGe Planar Heterostructures

Germanium-based planar heterostructures are emerging as versatile platforms for realizing quantum devices. In particular, planar Ge/SiGe quantum wells (QWs) host hole states with exceptionally high mobility and strong, electrically tunable spin–orbit interactions, enabling full electrical control of quantum information. A key requirement for these systems is the growth of microscopic, defect-free, atomically flat Ge QW heterostructures on relaxed or reverse-graded SiGe buffer layers, as well as on commercial Ge substrates. While several physical deposition techniques have demonstrated high-quality planar Ge/SiGe QWs, a major challenge remains: minimizing defect density typically requires high growth temperatures, which are incompatible with standard CMOS process flows. Here, we present a convenient low-temperature process for realizing high-quality planar SiGe/Ge heterostructures using a combination of thermal and electron-beam evaporation. We systematically map the effects of ex-situ and in-situ substrate preparation protocols, growth temperature, and post-deposition annealing conditions, and correlate these parameters with surface roughness and defect density. We find that in-situ oxide desorption conditions and post-annealing parameters have the most pronounced impact on improving surface quality. Under optimized conditions, we achieve atomically smooth surfaces with root-mean-square roughness σrms ≤ 10 Å and negligible defect density. Interestingly, thermally evaporated Ge layers exhibit oriented triangular crystallites that elongate upon post-annealing in the presence of high Ge vapor pressure. These results demonstrate that this simple, low-temperature deposition approach is a viable and effective route for achieving high-quality Ge QW heterostructures, with strong potential for scalable quantum computing and sensing applications.

Tripathi, Malvika [Fermilab] (ORCID:00000001989251↗