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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 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet-Molding Compound Evaluated

High-performance polymer matrix composites (PMC's) continue to be the focus of a number of research efforts aimed at developing cost-effective, lightweight material alternatives for advanced aerospace and aeropropulsion applications. These materials not only offer significant advantages in specific stiffness and strength over their current metal counterparts, but they can be designed and manufactured to eliminate joints and fasteners by combining individual components into integral subassemblies, thus making them extremely attractive for commercial applications. With much emphasis on the low-cost manufacturing aspects of advanced composite structures, there is heightened interest in high-performance sheet-molding compounds (SMC's). Researchers at the NASA Lewis Research Center, in cooperation with the Allison Advanced Development Company, completed an investigation examining the use of T650-35/PMR-15 SMC for a midstage inner-vane endwall application within a gas turbine engine compressor. This component resides in the engine flow path and is subjected not only to high airflow rates, but also to elevated temperatures and pressures. This application is unique in that it represents a very aggressive use of high-performance SMC's, raising obvious concerns related to durability and property retention in the presence of microstructural damage. Therefore, it was necessary to evaluate the fatigue behavior and damage tolerance of this material subjected to a representative thermomechanical fatigue (TMF) mission-cycle loading spectrum.

Castelli, Michael G.↗
NASA NTRS2010

Phase Change Material Trade Study: A Comparison Between Wax and Water for Manned Spacecraft

Phase change material heat sinks have been recognized as an important tool in optimizing thermal control systems for space exploration vehicles and habitats that must deal with widely varying thermal loads and environments. In order to better focus technology investment in this arena, NASA has supported a trade study with the objective of identifying where the best potential pay-off can be found among identified aqueous and paraffin wax phase change materials and phase change material heat sink design approaches. The study used a representative exploration mission with well understood parameters to support the trade. Additional sensitivity studies were performed to ensure the applicability of study results across varying systems and destinations. Results from the study indicate that a water ice PCM heat sink has the potential to decrease the equivalent system mass of the mission s vehicle through a combination of a smaller heat sink and a slight 5% increase in radiator size or the addition of a lightweight heat pump. An evaluation of existing and emerging PCM heat sink technologies indicates that further significant mass savings should be achievable through continued development of those technologies. The largest mass savings may be realized by managing the location of the liquid and the solid in the heat sink to eliminate the melting and freezing pressure of wax and water, respectively, while also accommodating the high structural loads expected on future manned launch vehicles.

Quinn, Gregory↗
NASA NTRS2015

Method of Making Lightweight, Single Crystal Mirror

A method of making a mirror from a single crystal blank may include fine grinding top and bottom surfaces of the blank to be parallel. The blank may then be heat treated to near its melting temperature. An optical surface may be created on an optical side of the blank. A protector may be bonded to the optical surface. With the protector in place, the blank may be light weighted by grinding a non-optical surface of the blank using computer controlled grinding. The light weighting may include creating a structure having a substantially minimum mass necessary to maintain distortion of the mirror within a preset limit. A damaged layer of the non-optical surface caused by light weighting may be removed with an isotropic etch and/or repaired by heat treatment. If an oxide layer is present, the entire blank may then be etched using, for example, hydrofluoric acid. A reflecting coating may be deposited on the optical surface.

Bly, Vincent T.↗
NASA NTRS1990

The mini-dome Fresnel lens photovoltaic concentrator array - Current status of component and prototype panel testing

NASA Lewis and ENTECH have been developing a high-efficiency, lightweight space photovoltaic concentrator array. The emphasis of the program has shifted to fabrication and testing of the minidome Fresnel lens and other array components. Protototype lenses have been tested for optical efficiency, with results around 90 percent, and tracking error performance. The results of these tests have been very consistent with the predicted analytical performance. Work has also progressed in the fabrication of the array support structure. Recent advances in 30 percent efficient stacked cell technology will have a significant effect on the array performance. It is concluded that near-term array performance goals of 300 W/sq m and 100 W/kg are feasible.

Piszczor, M. F.↗
NASA NTRS2008

High Temperature Aerogels for Thermal Protection Systems

High temperature aerogels in the Al2O3-SiO2 system are being investigated as possible constituents for lightweight integrated thermal protection system (TPS) designs for use in supersonic and hypersonic applications. Gels are synthesized from ethoxysilanes and AlCl3.6H2O, using an epoxide catalyst. The influence of Al:Si ratio, solvent, water to metal and water to alcohol ratios on aerogel composition, morphology, surface area, and pore size distribution were examined, and phase transformation on heat treatment characterized. Aerogels have been fabricated which maintain porous, fractal structures after brief exposures to 1000 C. Incorporation of nanofibers, infiltration of aerogels into SiC foams, use of polymers for crosslinking the aerogels, or combinations of these, offer potential for toughening and integration of TPS with composite structure. Woven fabric composites having Al2O3-SiO2 aerogels as a matrix also have been fabricated. Continuing work is focused on reduction in shrinkage and optimization of thermal and physical properties.

Hurwitz, Frances I.↗
DOE OSTI2018

Mechanically Robust, Ultraelastic Hierarchical Foam with Tunable Properties via 3D Printing

We present a mechanically robust, ultraelastic foam with controlled multiscale architectures and tunable mechanical/conductive performance is fabricated via 3D printing. Hierarchical porosity, including both macro- and microscaled pores, are produced by the combination of direct ink writing (DIW), acid etching, and phase inversion. The thixotropic inks in DIW are formulated by a simple one-pot process to disperse duo nanoparticles (nanoclay and silica nanoparticles) in a polyurethane suspension. The resulting lightweight foam exhibits tailorable mechanical strength, unprecedented elasticity (standing over 1000 compression cycles), and remarkable robustness (rapidly and fully recover after a load more than 20 000 times of its own weight). Surface coating of carbon nanotubes yields a conductive elastic foam that can be used as piezoresistivity sensor with high sensitivity. For the first time, this strategy achieves 3D printing of elastic foam with controlled multilevel 3D structures and mechanical/conductive properties. In conclusion, the facile ink preparation method can be utilized to fabricate foams of various materials with desirable performance via 3D printing.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermodynamic Stability and Site‐Specific Distribution of Graphitic and Pyridinic Nitrogen in Graphene Moiré on Ru(0001)

Abstract Graphene‐like materials are of interest for large‐scale hydrogen storage applications due to their lightweight, durable, and scalable properties. Nitrogen‐doping minimizes kinetic limitations in diffusion and recombination on surfaces, however, the role of graphitic nitrogen (GN) and pyridinic nitrogen (PN) is not well understood. Nitrogen‐doped graphene is synthesized on Ru(0001) using chemical vapor deposition (CVD) of pyridine and ion irradiation. Scanning tunneling microscopy (STM), x‐ray photoelectron spectroscopy (XPS), and density functional theory (DFT) are used to identify the structure, location, and thermodynamic stability of nitrogen species within the graphene moiré. CVD of pyridine results in a low nitrogen concentration (<0.1at%), while the post‐growth nitrogen ion irradiation allows us to increase the concentration further. The concentration of GN and PN is controlled by varying the ion dose and annealing temperature. Comparison of measured and simulated STM images of GN and PN yield an excellent agreement, allowing us to confidently establish that GN is preferentially located near the center of the Atop region, while PN is located in the valley region of the graphene moiré. This report explicitly confirms the site assignments and provides a foundation for the site synthesis and analysis of structural and electronic properties that drive the reactivity of N‐doped graphene.

Gedara, Buddhika S. A. [Physical and Computational↗
DOE OSTI2025

Prediction of carbon nanostructure mechanical properties and the role of defects using machine learning

Graphene-based nanostructures hold immense potential as strong and lightweight materials, however, their mechanical properties such as modulus and strength are difficult to fully exploit due to challenges in atomic-scale engineering. This study presents a database of over 2,000 pristine and defective nanoscale CNT bundles and other graphitic assemblies, inspired by microscopy, with associated stress–strain curves from reactive molecular dynamics (MD) simulations using the reactive INTERFACE force field (IFF-R). These 3D structures, containing up to 80,000 atoms, enable detailed analyses of structure-stiffness-failure relationships. By leveraging the database and physics- and chemistry-informed machine learning (ML), accurate predictions of elastic moduli and tensile strength are demonstrated at speeds 1,000 to 10,000 times faster than efficient MD simulations. Hierarchical Graph Neural Networks with Spatial Information (HS-GNNs) are introduced, which integrate chemistry knowledge. HS-GNNs as well as extreme gradient boosted trees (XGBoost) achieve forecasts of mechanical properties of arbitrary carbon nanostructures with only 3 to 6% mean relative error. The reliability equals experimental accuracy and is up to 20 times higher than other ML methods. Predictions maintain 8 to 18% accuracy for large CNT bundles, CNT junctions, and carbon fiber cross-sections outside the training distribution. The physics- and chemistry-informed HS-GNN works remarkably well for data outside the training range while XGBoost works well with limited training data inside the training range. The carbon nanostructure database is designed for integration with multimodal experimental and simulation data, scalable beyond 100 nm size, and extendable to chemically similar compounds and broader property ranges. The ML approaches have potential for applications in structural materials, nanoelectronics, and carbon-based catalysts.

Winetrout, Jordan J.↗
DOE OSTI2021

Interactions of Aqueous Surface Treatments with Magnesium Alloy

Magnesium, the lightest structural metal, has recently been identified as an important substrate for weight reduction in automotive, aerospace, personal electronics, and many other industries. Magnesium’s unique chemistry, however, makes it challenging to protect from corrosion and incorporate with other materials. Cleaners are the first step in any pretreatment process, and understanding their role in surface preparation for corrosion prevention is crucial to making magnesium substrate a viable solution for lightweighting. In this work, we explore the relationship between cleaner composition, pH, etch rate, and panel morphology post-cleaning to understand how various cleaners interact with magnesium alloy. Our findings broaden the pool of possible bath chemistries that provide safe and effective surface cleaning of magnesium substrate.

Harris, Rachel↗
DOE OSTI2025

DOE Repository Metadata Profile (DRMP): A Metadata Framework for Advancing Interoperability and AI Readiness Across Scientific Repositories

The Department of Energy (DOE) funds a diverse and distributed ecosystem of repositories that steward scientific data, publications, and software across its research programs, user facilities, and national laboratories. While significant progress has been made in standardizing dataset-level metadata, the metadata describing repositories themselves (their identity, governance, access interfaces, policies, and technical capabilities) remains inconsistent and fragmented across DOE-funded systems. This variability limits discoverability, interoperability, automated validation, and AI-driven analysis, all of which are increasingly essential for modern scientific workflows. To address this gap, the DOE Data Curation Working Group (DCWG) developed the DOE Repository Metadata Profile (DRMP). The DRMP is a practical, community-driven framework that defines how repositories can describe themselves in a consistent, machine-actionable, and scalable manner. The DRMP is not a new metadata schema. Instead, it is a mapping profile and structured element set capturing the essential characteristics of DOE repositories. It harmonizes repository-level metadata across six widely adopted community schemas: RE3Data; DCAT-US v3; Schema.org; Dublin Core; DataCite 4.6; and PREMIS 3.0. This harmonization eliminates reinvention and enables interoperability within DOE and across the broader scientific ecosystem. A core objective of the DRMP is to reduce burden on repositories by allowing them to reuse their existing metadata through a Rosetta-style crosswalk rather than redesigning local implementations. The profile introduces a three-level conformance model that supports incremental adoption: • Level 1 – Minimum Viable Record (MVR): foundational identification elements required for workflows, project registration, and basic repository presence. • Level 2 – Interoperable: structured metadata enabling alignment with national and international discovery systems. • Level 3 – AI-Ready: enhanced provenance, policy transparency, fixity, semantic context, and capabilities that support automated reasoning, model training governance, and machine-assisted curation. To support implementation, the DRMP includes JSON Schema definitions, OpenAPI patterns, and MCP templates that allow repositories to publish machine-readable metadata directly within existing platforms. These resources are modular and lightweight, enabling adoption without major architectural change. Adopting the DRMP enables repositories to: • Enhance discoverability and interoperability by aligning identifiers, classifications, and descriptive elements across widely used schema standards. • Support federated discovery and cross-registration across DOE systems, Data.gov, and international catalogs. • Enable AI agents and workflow orchestration systems to interpret repository-level metadata within the American Science Cloud (AmSC) through Model Context Protocol (MCP)-based context publication. • Demonstrate alignment with DOE’s open science, stewardship, and FAIR data priorities. This guidance represents a community-driven step forward. Through voluntary adoption and continued feedback, the DRMP advances a cohesive, machine-actionable description of DOE repositories that supports FAIR data practices, preparing the infrastructure for AI-enabled research, and strengthening the discoverability and reuse of DOE’s scientific outputs.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
NASA NTRS1999

Airframe Integration Trade Studies for a Reusable Launch Vehicle

Future launch vehicles must be lightweight, fully reusable and easily maintained if low-cost access to space is to be achieved. The goal of achieving an economically viable Single-Stage-to-Orbit (SSTO) Reusable Launch Vehicle (RLV) is not easily achieved and success will depend to a large extent on having an integrated and optimized total system. A series of trade studies were performed to meet three objectives. First, to provide structural weights and parametric weight equations as inputs to configuration-level trade studies. Second, to identify, assess and quantify major weight drivers for the RLV airframe. Third, using information on major weight drivers, and considering the RLV as an integrated thermal structure (composed of thrust structures, tanks, thermal protection system, insulation and control surfaces), identify and assess new and innovative approaches or concepts that have the potential for either reducing airframe weight, improving operability, and/or reducing cost.

Dorsey, John T.↗
NASA NTRS2022

Lightweight Composite Reflectarray That Can Be Flattened, Folded, and Coiled for Compact Stowage

Herein is presented a design for a lightweight 5m 1m radio-frequency (RF) re ector that can be attened, folded, and coiled for compact stowage on board an ESPA-class spacecraft. The re ector is a re ectarray that operates at 3.2GHz. Compared to state- of-the-art technologies for RF re ectors, the presented design has advantages in terms of areal density, sti ness, deployed stability, and scalability. Thermal and structural analysis is presented to demonstrate deployed sti ness and thermoelastic stability of the proposed design. Thermal analysis is used to predict in- space deployed temperatures in an operational condition, and structural nite element analysis is used to predict deployed vibration modes and frequencies, and the thermoelastic deformation of the deployed re ector. Also presented are the fabrication, assembly, and testing of two one-third-scale-length full-scale-width 1:7m 1m test articles. These test articles are used to experimentally demonstrate RF functioning, stowage, deployment, and RF performance after deployment.

Pellegrino, Sergio↗
DOE OSTI2016

Infrastructure for Multiphysics Software Integration in High Performance Computing-Aided Science and Engineering

The project described in this report constructed and exercised an innovative multiphysics coupling toolkit called the Illinois Rocstar MultiPhysics Application Coupling Toolkit (IMPACT). IMPACT is an open source, flexible, natively parallel infrastructure for coupling multiple uniphysics simulation codes into multiphysics computational systems. IMPACT works with codes written in several high-performance-computing (HPC) programming languages, and is designed from the beginning for HPC multiphysics code development. It is designed to be minimally invasive to the individual physics codes being integrated, and has few requirements on those physics codes for integration. The goal of IMPACT is to provide the support needed to enable coupling existing tools together in unique and innovative ways to produce powerful new multiphysics technologies without extensive modification and rewrite of the physics packages being integrated. There are three major outcomes from this project: 1) construction, testing, application, and open-source release of the IMPACT infrastructure, 2) production of example open-source multiphysics tools using IMPACT, and 3) identification and engagement of interested organizations in the tools and applications resulting from the project. This last outcome represents the incipient development of a user community and application echosystem being built using IMPACT. Multiphysics coupling standardization can only come from organizations working together to define needs and processes that span the space of necessary multiphysics outcomes, which Illinois Rocstar plans to continue driving toward. The IMPACT system, including source code, documentation, and test problems are all now available through the public gitHUB.org system to anyone interested in multiphysics code coupling. Many of the basic documents explaining use and architecture of IMPACT are also attached as appendices to this document. Online HTML documentation is available through the gitHUB site. There are over 100 unit tests provided that run through the Illinois Rocstar Application Development (IRAD) lightweight testing infrastructure that is also supplied along with IMPACT. The package as a whole provides an excellent base for developing high-quality multiphysics applications using modern software development practices. To facilitate understanding how to utilize IMPACT effectively, two multiphysics systems have been developed and are available open-source through gitHUB. The simpler of the two systems, named ElmerFoamFSI in the repository, is a multiphysics, fluid-structure-interaction (FSI) coupling of the solid mechanics package Elmer with a fluid dynamics module from OpenFOAM. This coupling illustrates how to combine software packages that are unrelated by either author or architecture and combine them into a robust, parallel multiphysics system. A more complex multiphysics tool is the Illinois Rocstar Rocstar Multiphysics code that was rebuilt during the project around IMPACT. Rocstar Multiphysics was already an HPC multiphysics tool, but now that it has been rearchitected around IMPACT, it can be readily expanded to capture new and different physics in the future. In fact, during this project, the Elmer and OpenFOAM tools were also coupled into Rocstar Multiphysics and demonstrated. The full Rocstar Multiphysics codebase is also available on gitHUB, and licensed for any organization to use as they wish. Finally, the new IMPACT product is already being used in several multiphysics code coupling projects for the Air Force, NASA and the Missile Defense Agency, and initial work on expansion of the IMPACT-enabled Rocstar Multiphysics has begun in support of a commercial company. These initiatives promise to expand the interest and reach of IMPACT and Rocstar Multiphysics, ultimately leading to the envisioned standardization and consortium of users that was one of the goals of this project.

42 ENGINEERING↗
NASA NTRS1972

Beryllium heat shield technology in the area of thermal protection devices

For future space applications, it is important that thermal protection systems be reusable for space shuttle flights. Beryllium offers a unique combination of properties for use as a heat shield material (stiffness, lightweight, ability to absorb heat). In order to adequately test these properties, it was necessary to fabricate heat shields. The concept used was a two-section test panel 99.1 x 99.1 cm (39 x 39 inch) with each section made of two 0.051 cm (0.020 inch) thick beryllium corrugations brazed together as a mirror image, with titanium (Ti-6Al-4V) used as standoffs to support the panel structure. The work prior to fabrication included brazability of both beryllium and titanium, forming of beryllium and titanium, machining processes involving beryllium and chem-milling beryllium. Sub-scale samples were made of all details before actual fabrication of the large panel. The full scale test panel was hot-formed at 950 K, chem-milled to 0.041 + or - 0.005 cm (0.016 + or - 0.002 inches), trimmed, vacuum brazed, drilled and assembled.

Muhl, A. E.↗
NASA NTRSDate not supplied

Segmented Solid Surface Reflector Concentrically Stacked With Tubular Shape Memory Composite Hinges

A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design uses compact, light, and simple advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm. The seven-panel hexagonal sub-reflector is divided into hexagonal panels that stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics with controlled dynamics. A secondary mechanism closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for triggering and control, the actuation mechanisms, and the lightweight sandwich construction reflector panels. A parametric study using finite element analyses was conducted to assess how design features of the hinge affect its stowage and deployment dynamics. The preliminary component fabrication and testing results for the two-panel assembly breadboard model are outlined. Finally, the results of the test campaign with the brassboard reflector model are presented. A comparison of deployed reflector surface deviation between the measured surface after the stowage and deployment process and the pre-test scans and the nominal surface revealed root mean square errors of less than 1 mm, as required by X-band radiofrequency transmission.

gravity offloading↗
DOE OSTI2017

Optimized Generator Designs for the DTU 10-MW Offshore Wind Turbine using GeneratorSE

Compared to land-based applications, offshore wind imposes challenges for the development of next generation wind turbine generator technology. Direct-drive generators are believed to offer high availability, efficiency, and reduced operation and maintenance requirements; however, previous research suggests difficulties in scaling to several megawatts or more in size. The resulting designs are excessively large and/or massive, which are major impediments to transportation logistics, especially for offshore applications. At the same time, geared wind turbines continue to sustain offshore market growth through relatively cheaper and lightweight generators. However, reliability issues associated with mechanical components in a geared system create significant operation and maintenance costs, and these costs make up a large portion of overall system costs offshore. Thus, direct-drive turbines are likely to outnumber their gear-driven counterparts for this market, and there is a need to review the costs or opportunities of building machines with different types of generators and examining their competitiveness at the sizes necessary for the next generation of offshore wind turbines. In this paper, we use GeneratorSE, the National Renewable Energy Laboratory's newly developed systems engineering generator sizing tool to estimate mass, efficiency, and the costs of different generator technologies satisfying the electromagnetic, structural, and basic thermal design requirements for application in a very large-scale offshore wind turbine such as the Technical University of Denmark's (DTU) 10-MW reference wind turbine. For the DTU reference wind turbine, we use the previously mentioned criteria to optimize a direct-drive, radial flux, permanent-magnet synchronous generator; a direct-drive electrically excited synchronous generator; a medium-speed permanent-magnet generator; and a high-speed, doubly-fed induction generator. Preliminary analysis of leveled costs of energy indicate that for large turbines, the cost of permanent magnets and reliability issues associated with brushes in electrically excited machines are the biggest deterrents for building direct-drive systems. The advantage of medium-speed permanent-magnet machines over doubly-fed induction generators is evident, yet, variability in magnet prices and solutions to address reliability issues associated with gearing and brushes can change this outlook. This suggests the need to potentially pursue fundamentally new innovations in generator designs that help avoid high capital costs but still have significant reliability related to performance.

17 WIND ENERGY↗
NASA NTRS1972

Seismic investigations - The Viking Mars Lander.

A lightweight three-component short period seismometer has been developed for preliminary seismic investigations of Mars. Because of weight and data-rate constraints the Viking seismic experiment is far from optimal but it should, at a minimum, provide information about the microseismic level and an upper bound on the seismicity of the planet. If Mars is tectonically active a start can be made on the problem of the internal structure, dynamics, and composition of the planet. A good distribution of modest sized Marsquakes will make it possible to determine if Mars has a core. The size of the core is related to the conditions of planetary formation.

Anderson, D. L.↗
NASA NTRS2004

Cryogenic Test Results of Hextek Mirror

A 250 mm diameter lightweight borosilicate mirror has been interferometrically tested from room-temperature down to 30 K at the X-Ray Calibration Facility (XRCF) at Marshall Space Flight Center (MSFC). The minor blank was manufactured by Hextek Corporation using a high-temperature gas fusion process and was then polished at MSFC. It is a sandwich-type mirror consisting of a thin face-sheet (approx.1.5 mm thick), a core structure (20 mm thick, approx.43 mm diameter cells, & 0.5-1.2 mm thick walls), and a thin back-sheet (3 mm thick). The mirror has a 2500 mm spherical radius-of- curvature @/lo). The areal density is 14 kg/sq m. The mirror was tested in the 1 m x 2 m chamber using an Instantaneous Phase Interferometer (PI) from ADE Phase Shift Technologies. The mirror was tested twice. The first test measured the change in surface figure from ambient to 30 K and the repeatability of the change. An attempt was then made by QED Technologies to cryo-figure the mirror using magnetorheological finishing. The second test measured the effectiveness of the cryo- figuring. This paper will describe the test goals, the test instrumentation, and the test results for these cryogenic tests.

Hadaway, James↗