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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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NASA NTRS1963

Selected Welding Techniques

Marshall Space Flight Center specifications for welding large, single tank boosters are rather stringent, calling for no undercutting, no cracking, complete fusion, and a relatively small amount of porosity. In order to maintain design tolerances it is necessary to rely on electronic positioning controls to keep the torch on the joint to be welded. When tests of certain available systems proved conclusively that they were not adequate, Marshall personnel set out on their own development programs. The problems were many but the results were gratifying. It is believed that proximity and seam tracking controls adequate for most anticipated applications are now on hand.

Source record↗

DOE OSTI2024

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lattice structured lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation (MOOSE) Environment input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

COMPUTER-AIDED LATTICE DESIGN AND ADVANCED MODELING FOR THE DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL MATERIALS

36 MATERIALS SCIENCE↗

NASA NTRS1992

Catalysts for ultrahigh current density oxygen cathodes for space fuel cell applications

The objective was to identify promising electrocatalyst/support systems for oxygen cathodes capable of operating at ultrahigh current densities in alkaline fuel cells. Such cells will require operation at relatively high temperatures and O2 pressures. A number of materials were prepared, including Pb-Ru and Pb-Ir pyrochlores, RuO2 and Pt-doped RuO2, lithiated NiO and La-Ni perovskites. Several of these materials were prepared using techniques that had not been previously used to prepare them. Particularly interesting was the use of the alkaline solution technique to prepare Pt-doped and Pb-Ru pyrochlores in high area form. Also interesting was the use of the fusion (melt) method for preparing the Pb-Ru pyrochlore. Several of the materials were also deposited with platinum. Well-crystallized Pb2Ru2O(7-y) was used to fabricate very high performance O2 cathodes with good stability in room temperature KOH. This material was also found to be stable over a useful potential range at approx. 140 C in concentrated KOH. For some of the samples, fabrication of the gas-fed electrodes could not be fully optimized during this project period. Future work may be directed at this problem. Pyrochlores that were not well-crystallized were found to be unstable in alkaline solution. Very good O2 reduction performance and stability were observed with Pb2RuO(7-y) in a carbon-based gas-fed electrode with an anion-conducting membrane placed on the electrolyte side of the electrode. The performance came within a factor of about two of that observed without carbon. High area platinum and gold supported on several conductive metal oxide supports were examined. Only small improvements in O2 reduction performance at room temperature were observed for Pb2Ru2O(7-y) as a support because of the high intrinsic activity of the pyrochlore. In contrast, a large improvement was observed for Li-doped NiO as a support for Pt. Very poor performance was observed for Au deposited on Li-NiO at approx. 150 C. Nearly reversible behavior was observed for the O2/OH(-) couple for Li-doped NiO at approx. 200 C. The temperature dependence for the O2 reduction was examined.

Tryk, Donald A.↗

DOE OSTI2024

Phase Composition and Phase Transformation of Additively Manufactured Nickel Alloy 718 AM Bench Artifacts

Additive manufacturing (AM) technologies offer unprecedented design flexibility but are limited by a lack of understanding of the material microstructure formed under their extreme and transient processing conditions and its subsequent transformation during post-build processing. As part of the 2022 AM Bench Challenge, sponsored by the National Institute of Standards and Technology, this study focuses on the phase composition and phase evolution of AM nickel alloy 718, a nickel-based superalloy, to provide benchmark data essential for the validation of computational models for microstructural predictions. Here, we employed high-energy synchrotron X-ray diffraction, in situ synchrotron X-ray scattering, as well as high-resolution transmission electron microscopy for our analyses. The study uncovers critical aspects of the microstructure in its as-built state, its transformation during homogenization, and its phase evolution during subsequent aging heat treatment. Specifically, we identified secondary phases, monitored the dissolution and coarsening of microstructural elements, and observed the formation and stability of γ ’ and γ ” phases. The results provide the rigorous benchmark data required to understand the atomic and microstructural transformations of AM nickel alloy 718, thereby enhancing the reliability and applicability of AM models for predicting phase evolution and mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Accelerated version of NUBEAM capabilities in DIII-D using neural networks

A neural network model of the effects of neutral beam injection on DIII-D has been developed. The training and testing data used by the model have been generated by the NUBEAM module of TRANSP for experimental discharges from the 2018 DIII-D campaign. Using a principle component analysis to reduce the dimensionality of profile data, the model has been shown to reproduce the results of the Monte Carlo code NUBEAM with a high level of accuracy and an execution time orders of magnitude faster than the execution time of NUBEAM. Furthermore, this makes the neural network model uniquely suited to applications in model-based scenario planning (off-line) and active control (on-line), where a large number of simulation runs are required by the associated optimization tasks that need to be performed before and during the discharge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Understanding Microstructural Effects on Dynamic Performance Towards the Development of Shock Metamaterials

With the recent advances in additive manufacturing (AM), long-range periodic lattice assemblies are being developed for vibration and shock mitigation components in aerospace and military applications with unique geometric and topological structures. There has been extensive work in understanding the static properties associated with varying topology of these lattice architectures, but there is almost no understanding of microstructural affects in such structures under high-strain rate dynamic loading conditions. Here we report the shock behavior of lattices with varying intrinsic grain structures achieved by post process annealing. High resolution 316L stainless steel lattices were 3D printed by a laser-powder bed fusion machine and characterized by computed tomography. Subsequent annealing resulted in stress-relieved and recrystallized lattices. Overall the lattices had strong cubic texture aligning with the x-, y- and z-directions of the build with a preference outside the build direction (z). The recrystallized sample had more equiaxed polygonal grains and a layer of BCC ferrite at the surface of the structure approximately 1 grain thick. Upon dynamic compression the as-deposited lattice showed steady compaction behavior while the heat-treated lattices exhibit negative velocity behavior indicative of failure. We attribute this to the stiffer BCC ferrite in the annealed lattices becoming damaged and fragmenting during compression.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Investigation of Reaction Pathways and Temperature Inhibition in Methane DBD Plasmas at the Princeton Collaborative Research Facility (PCRF)

The overarching goal of this research is to advance the fundamental understanding of plasma-driven chemical conversion of light hydrocarbons using dielectric barrier discharges (DBDs). Using methane (CH 4 ) as a model system, the primary focus is to elucidate the influence of DBD plasma properties and environmental temperature on CH 4 plasma chemistry by studying decomposition products of the gas effluent across a broad range of conditions using experimental instrumentation at the Princeton Collaborative Research Facility (PCRF) located at the Princeton Plasma Physics Laboratory (PPPL). The insights obtained from this study are expected to form the mechanistic foundation for the design and optimization of plasma-catalytic reactions of light hydrocarbons for practical applications such as the recycling of production flare gas by transforming the uncaptured waste into value-added resources at the source of extraction, presenting a sustainable solution to a longstanding environmental challenge.

03 NATURAL GAS↗

DOE OSTI2023

Opinion: A critical evaluation of the evidence for aerosol invigoration of deep convection

Deep convective updraft invigoration via indirect effects of increased aerosol number concentration on cloud microphysics is frequently cited as a driver of correlations between aerosol and deep convection properties. Here, we critically evaluate the theoretical, modeling, and observational evidence for warm- and cold-phase invigoration pathways. Though warm-phase invigoration is plausible and theoretically supported via lowering of the supersaturation with increased cloud droplet concentration in polluted conditions, the significance of this effect depends on substantial supersaturation changes in real-world convective clouds that have not been observed. Much of the theoretical support for cold-phase invigoration depends on unrealistic assumptions of instantaneous freezing and unloading of condensate in growing, isolated updrafts. When applying more realistic assumptions, impacts on buoyancy from enhanced latent heating via fusion in polluted conditions are largely canceled by greater condensate loading. Many foundational observational studies supporting invigoration have several fundamental methodological flaws that render their findings incorrect or highly questionable. Thus, much of the evidence for invigoration has come from numerical modeling, but different models and setups have produced a vast range of results. Furthermore, modeled aerosol impacts on deep convection are rarely tested for robustness, and microphysical biases relative to observations persist, rendering many results unreliable for application to the real world. Without clear theoretical, modeling, or observational support, and given that enervation rather than invigoration may occur for some deep convective regimes and environments, it is entirely possible that the overall impact of cold-phase invigoration is negligible. Substantial mesoscale variability of dominant thermodynamic controls on convective updraft strength coupled with substantial updraft and aerosol variability in any given event are poorly quantified by observations and present further challenges to isolating aerosol effects. Observational isolation and quantification of convective invigoration by aerosols is also complicated by limitations of available cloud condensation nuclei and updraft speed proxies, aerosol correlations with meteorological conditions, and cloud impacts on aerosols. Furthermore, many cloud processes, such as entrainment and condensate fallout, modulate updraft strength and aerosol–cloud interactions, varying with cloud life cycle and organization, but these processes remain poorly characterized. Considering these challenges, recommendations for future observational and modeling research related to aerosol invigoration of deep convection are provided.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1993

Development and calibration of UV/VUV radiometric sources

A program exists at NIST to calibrate radiometric sources for the spectral range from 118-350 nm. These include deuterium lamps, hollow-cathode lamps, RF-excited dimer lamps, and wall-stabilized argon arcs. Sources have been calibrated for and used by researchers in solar physics, astrophysics, atmospheric physics (ozone measurements), magnetically controlled fusion, and photobiology. The argon arcs were developed in our laboratory, and provide intense sources of both radiance and irradiance. Calibrations are performed relative to two primary sources, a wall-stabilized hydrogen arc and a 12,000 K black-body line arc, both developed in our laboratory. Also we recently have begun periodic calibrations on the NIST storage ring, SURF II, to insure consistency between our respective radiometric bases. Various sources have been calibrated for space' applications, including several which are flyable. Also, some development and testing of radiometers for semiconductor lithography were recently carried out with an intense argon arc source.

Bridges, J. M.↗

NASA NTRS2023

Manufacturing and Mechanical Testing of TC1225/LM-PAEK and TC1200/PEEK Thermoplastic Composite Panels

Development of thermoplastic composites (TPCs) for aerospace structures is experiencing renewed enthusiasm attributed to the availability of rapid manufacturing technology, ease of joining through fusion welding processes, and the successful utilization of the material in flight critical structures. Semicrystalline thermoplastics such as polyether ether ketone (PEEK), polyether ketone ketone (PEKK), and polyphenylene sulfide (PPS) have been successfully demonstrated as thermoplastic skins, keel beams, and angle brackets for commercial aircraft. Composite specimens were fabricated from the Toray TC1225 and TC1200 unidirectional prepreg systems and tested to gain confidence with NASA in-house TPC processing as part of the Thermoplastics Development for Exploration Application (TDEA) project. TC1225 is a relatively new material system that uses T700GC fibers and low-melt polyaryl ether ketone (LM-PAEK) resin. TC1200 is the latest version of a material system that has been available for several decades with AS4 fibers and PEEK resin. Results for ultrasonic inspection, optical microscopy, acid digestion, and differential scanning calorimetry establish the quality of the panels. Mechanical test data for unnotched and notched laminate tension and compression as well as compression after impact provide data for equivalency assessment and support material selection in TDEA. Satisfactory equivalence of the TC1225 results and the National Center for Advanced Materials Performance (NCAMP) database was found. The results indicate high-quality manufacturing was achieved, and the resulting mechanical test data are in agreement with that in the literature.

Thermoplastic Composites↗

DOE OSTI2021

Predicting phase transformation kinetics during metal additive manufacturing using non-isothermal Johnson-Mehl-Avrami models: Application to Inconel 718 and Ti-6Al-4V

Here, a computational model was developed to predict solid-state phase transformation kinetics within mechanical parts during metal additive manufacturing processes. This model is a modified version of the Johnson-Mehl-Avrami model for non-isothermal phase transformations that can be applied to various material systems undergoing solid-state phase transformations. Using the thermal history of an additive manufacturing fabricated mechanical part, along with the necessary thermodynamic data and kinetic information as inputs, the model outputs the history of phase fraction evolution during the build process. The model was applied to an Inconel 718 part built by powder bed fusion and a Ti-6Al-4V part built by directed energy deposition. Microstructure characterization and mechanical testing were performed for the validation of the model.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Circular Permutation of a Chaperonin Protein: Biophysics and Application to Nanotechnology

We have designed five circular permutants of a chaperonin protein derived from the hyperthermophilic organism Sulfolobus shibatae. These permuted proteins were expressed in E. coli and are well-folded. Furthermore, all the permutants assemble into 18-mer double rings of the same form as the wild-type protein. We characterized the thermodynamics of folding for each permutant by both guanidine denaturation and differential scanning calorimetry. We also examined the assembly of chaperonin rings into higher order structures that may be used as nanoscale templates. The results show that circular permutation can be used to tune the thermodynamic properties of a protein template as well as facilitating the fusion of peptides, binding proteins or enzymes onto nanostructured templates.

Paavola, Chad↗

DOE OSTI2023

Conflation of Geospatial POI Data and Ground-level Imagery

The code solves the problem of conflating POI (Points of Interest) geospatial data and geo-tagged ground-level imagery data. The main challenges with fusion or conflation of these two types of data has been that these two data entities are represented not only in several ways in current state-of-the-art, but also there is mismatch of representation format of these two data types. This source code/software brings POI datapoints and ground-level imagery datapoints into same representation format, and then generates valuable Knowledge Graph combining POI and images data (so that it can be used for multitude of applications).

De, Debraj↗

NASA NTRS1991

Fuzzy Logic Path Planning System for Collision Avoidance by an Autonomous Rover Vehicle

Systems already developed at JSC have shown the benefits of applying fuzzy logic control theory to space related operations. Four major issues are addressed that are associated with developing an autonomous collision avoidance subsystem within a path planning system designed for application in a remote, hostile environment that does not lend itself well to remote manipulation of the vehicle involved through Earth-based telecommunication. A good focus for this is unmanned exploration of the surface of Mars. The uncertainties involved indicate that robust approaches such as fuzzy logic control are particularly appropriate. The four major issues addressed are: (1) avoidance of a single fuzzy moving obstacle; (2) back off from a dead end in a static obstacle environment; (3) fusion of sensor data to detect obstacles; and (4) options for adaptive learning in a path planning system.

Murphy, Michael G.↗

DOE OSTI2021

New methodology for measuring electron density perturbations caused by plasma coherent modes using profile reflectometry: Magnitudes and radial profiles in DIII-D

New capabilities of fast-sweep frequency-modulated profile reflectometry are explored to measure electron density ne perturbation magnitudes and radial profiles due to plasma coherent modes in DIII-D. The first approach is based on the frequency analysis of phase perturbations associated with high frequency (~MHz) Alfvén eigenmodes (AEs). The measurement of ~5.5 MHz fast-ion-driven global Alfvén eigenmodes (GAEs) is demonstrated in a neutral beam-heated DIII-D plasma. The GAE induced a broad radial distribution of phase perturbations in the profile reflectometer data. Analysis of these data determined the effective cutoff location displacement and the estimated ne fluctuation profile. In the second approach, high resolution ne profiles are used directly to determine the radial structure of ne perturbations due to a neo-classical tearing mode. These new measurements broaden the application of profile reflectometry and advance the development of AE spectroscopy as a tool for non-invasive diagnosis of fast-ion-driven modes in DIII-D and burning plasmas such as ITER.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Implementation of AI/DEEP learning disruption predictor into a plasma control system

Abstract This paper reports on advances in the state‐of‐the‐art deep learning disruption prediction models based on the Fusion Recurrent Neural Network (FRNN) originally introduced in a 2019 NATURE publication [ https://doi.org/10.1038/s41586‐019‐1116‐4 ]. In particular, the predictor now features not only the “disruption score,” as an indicator of the probability of an imminent disruption, but also a “sensitivity score” in real time to indicate the underlying reasons for the imminent disruption. This adds valuable physics interpretability for the deep learning model and can provide helpful guidance for control actuators now implemented into a modern plasma control system (PCS). The advance is a significant step forward in moving from modern deep learning disruption prediction to real‐time control and brings novel AI‐enabled capabilities relevant for application to the future burning plasma ITER system. Our analyses use large amounts of data from JET and DIII‐D vetted in the earlier NATURE publication. In addition to “when” a shot is predicted to disrupt, this paper addresses reasons “why” by carrying out sensitivity studies. FRNN is accordingly extended to use more channels of information, including measured DIII‐D signals such as (i) the “n1rms” signal that is correlated with the n = 1 modes with finite frequency, including neoclassical tearing mode and sawtooth dynamics; (ii) the bolometer data indicative of plasma impurity control; and (iii) “q‐min”—the minimum value of the safety factor relevant to the key physics of kink modes. The additional channels and interpretability features expand the ability of the deep learning FRNN software to provide information about disruption subcategories as well as more precise and direct guidance for the actuators in a PCS.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1985

Polyvinyl alcohol coating of polystyrene inertial confinement fusion targets

An inertial confinement fusion (ICF) target made of polystyrene is first levitated in an acoustic field. The surface of the target is then etched using an appropriate solution (e.g., cyclohexane) to enhance the wetting characteristics. A specially prepared polyvinyl alcohol solution is atomized using an acoustic atomizer and deposited on the surface of the target. The solution is air dried to form a thin coating (2 microns) on the target (outside diameter of about 350-850 microns). Thicker coatings are obtained by repeated applications of the coating solutions. Preliminary results indicate that uniform coatings may be achievable on the targets with a background surface smoothness in the order of 1000 A.

Annamalai, P.↗