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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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All sources NASA NTRS DOE OSTI

NASA NTRS2003

Microsystems Fabrication Laboratory-New Class 100 Cleanroom Completed and Certified

A new Microsystems Fabrication Laboratory (MFL), a Class 100 cleanroom fabrication facility, was completed and certified in 2002 at the NASA Glenn Research Center. This facility, to be used by Glenn's Instrumentation and Controls Division, was designed and built as part of the NASA Construction of Facilities Program. The design, construction, and certification phases were managed by personnel from Glenn s Facilities and Test Engineering Division. Because of time constraints and the need for specialized cleanroom expertise, this 1000 ft2 laboratory was completed using a design-build procurement. Facility Planning & Resources (Pittsburgh, PA) was selected as the prime contractor and provided the architectural design and project management. A major subcontractor, AdvanceTEC, LLC (Richmond, VA), provided the mechanical and electrical design and performed the construction services. Throughout this fast-track project, Facilities and Test Engineering Division personnel provided overall project management and worked closely with the contractors to ensure that the customers needs were addressed and that the impact of the project implementation was minimized.

Borato, Frances M.↗

NASA NTRSDate not supplied

Parametric Optimization of Rigid Wheels for Planetary Surface Mobility Applications

Design-Build-Test approaches for spaceflight hardware are time and cost intensive, which can result in suboptimal mechanism designs. Optimization-based approaches that utilize high-fidelity models and physics simulation could overcome these limitations while simultaneously speeding up the mechanical design process and reducing cost. In this work, we present a toolchain that enables the multi-objective optimization of rigid rover wheels for planetary surface mobility applications. The toolchain uses Chrono’s Continuous Representation Model (CRM) functionality to simulate granular soil and performs multi-objective parametric optimization on candidate rover wheels to meet a desired performance criterion. The resulting wheel design is then evaluated experimentally using a single-wheel testbed. We end with a discussion of how the toolchain can be extended to simultaneously co-optimize other system parameters, such as system power consumption and feedback control gains.

Optimization↗

DOE OSTI2022

Accelerating Optimal Integration of Energy Efficiency Strategies with Industrialized Modular Construction: Preprint

The National Renewable Energy Laboratory's (NREL's) Industrialized Construction Innovation team first introduced the Industrialized Construction Assessment Framework to achieve affordable, net-zero energy (NZE) modular multifamily buildings in the 2020 ACEEE paper "Integrating Energy Efficiency Strategies with Industrialized Construction for our Clean Energy Future." Since then, NREL has continued to drive the ambitious plan to accelerate optimal integration of energy efficiency strategies during industrialized construction with little or no additional cost, labor, and production time. This follow-on paper introduces the Energy in Modular (EMOD) buildings method and presents NREL's research efforts over the last two years in collaboration with industry, including affordable housing partners. NREL has developed an idealized NZE modular multifamily building design that incorporates five energy efficiency strategies well suited for industrialized construction in factories: (1) envelope thermal control, (2) envelope infiltration control, (3) mechanical, electrical, and plumbing systems, (4) smart controls, and (5) solar plus storage. This paper highlights results from leveraging design for manufacturing and assembly principles, testing, and validation pilots with factory partners; demonstrating pod prototypes in test stand at NREL; and performing simulations. Overall, these research efforts address barriers to whole-building system integration, such as poor installation quality of thermal and air barriers; lack of unitized systems for space conditioning, energy recovery and ventilation, and water heating; problematic on-site installation, commissioning, and configuration of controls; and lack of cost-effective integration for grid-friendly design and emerging technologies. Conclusively, the paper delineates next steps for future work with NREL's partners toward developing a transformational pathway for our clean energy future.

affordable housing↗

DOE OSTI2021

Potential design problems for ITER fusion device

The international thermonuclear experimental reactor (ITER) is a worldwide project currently being built in France for the demonstration of the feasibility of thermonuclear technologies for future realization of successful commercial fusion energy. ITER is of the tokamak based design using strong magnetic fields to confine the very hot plasma needed to induce the fusion reaction. Tokamak devices are currently the front leading designs. Building a successful magnetic fusion device for energy production is of great challenge. A key obstacle to such design is the performance during abnormal events including plasma disruptions and so-called edge-localized modes (ELMs). In these events, a massive and sudden release of energy occurs quickly, due to loss of full or partial plasma confinement, leading to very high transient power loads on the reactor surface boundaries. A successful reactor design should tolerate several of these transient events without serious damages such as melting and vaporization of the structure. This paper highlights, through comprehensive state-of-the-art computer simulation of the entire ITER interior design during such transient events, e.g., ELMs occurring at normal operation and disruptions during abnormal operation, potential serious problems with current plasma facing components (PFCs) design. The HEIGHTS computer package is used in these simulations. The ITER reactor design was simulated in full and exact 3D geometry including all known relevant physical processes involved during these transient events. The current ITER divertor design may not work properly and may requires significant modifications or new innovative design to prevent serious damage and to ensure successful operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

DIVA/DeviceEditor v6.1.2

DIVA is an end-to-end DNA design and construction management platform that streamlines how researchers design, build, and receive sequence-verified DNA constructs. Through a web-based BioCAD interface (DeviceEditor), researchers independently design DNA constructs and submit them to a centralized queue with a single action. Designs progress transparently through standardized states which allow researchers to track status and access finished constructs via a central DNA repository. Submitted designs are reviewed by dedicated staff for feasibility and optimization, reducing costly failures and improving downstream execution. Automated DNA assembly software optimizes construction strategies by reusing existing parts where possible and sourcing synthetic DNA only when needed. Standardized, sequence-agnostic assembly methods enable many independent constructs to be built in parallel using lab automation, dramatically increasing throughput. High-throughput next-generation sequencing is used to verify construct accuracy, with flexible platforms selected based on task requirements. Throughout the process, detailed success and failure data are captured and analyzed, enabling continuous improvement of assembly protocols. Compared to traditional, manual DNA construction workflows, DIVA offers higher scalability, transparency, reproducibility, and data-driven optimization.

Plahar, Hector [Lawrence Berkeley National Laborat↗

NASA NTRS1999

Miniature X-Ray Bone Densitometer

The purpose of the Dual Energy X-ray Absorptiometry (DEXA) project is to design, build, and test an advanced X-ray absorptiometry scanner capable of being used to monitor the deleterious effects of weightlessness on the human musculoskeletal system during prolonged spaceflight. The instrument is based on the principles of dual energy x-ray absorptiometry and is designed not only to measure bone, muscle, and fat masses but also to generate structural information about these tissues so that the effects on mechanical integrity may be assessed using biomechanical principles. A skeletal strength assessment could be particularly important for an astronaut embarking on a remote planet where the consequences of a fragility fracture may be catastrophic. The scanner will employ multiple projection images about the long axis of the scanned subject to provide geometric properties in three dimensions, suitable for a three-dimensional structural analysis of the scanned region. The instrument will employ advanced fabrication techniques to minimize volume and mass (100 kg current target with a long-term goal of 60 kg) of the scanner as appropriate for the space environment, while maintaining the required mechanical stability for high precision measurement. The unit will have the precision required to detect changes in bone mass and geometry as small as 1% and changes in muscle mass as small as 5%. As the system evolves, advanced electronic fabrication technologies such as chip-on-board and multichip modules will be combined with commercial (off-the-shelf) parts to produce a reliable, integrated system which not only minimizes size and weight, but, because of its simplicity, is also cost effective to build and maintain. Additionally, the system is being designed to minimize power consumption. Methods of heat dissipation and mechanical stowage (for the unit when not in use) are being optimized for the space environment.

Charles, Harry K., Jr.↗

DOE OSTI2022

Extending the Brick schema to represent metadata of occupants

Here, energy-related behaviors of occupants constitute a key factor influencing building performance; accordingly, the measured occupant data can support the objective assessment of the indoor environment and energy performance of buildings, which can inform building design and operational decisions. Existing data schemas focus on metadata of sensors, meters, physical equipment, and IoT devices in buildings; however, they are limited in representing the metadata of occupant data, including occupants' presence in spaces, movement between spaces, interactions with building systems or IoT devices, and preference of indoor environmental needs. To address this gap, an extension to the widely adopted metadata schema, Brick, is proposed to represent the contextual, behavioral, and demographic information of occupants. The proposed extension includes four parts: (1) a new “Occupant” class to represent occupants' demography and energy related behavioral patterns, (2) new subclasses under the Equipment class to represent envelope system and personal thermal comfort devices, (3) new subclasses under the Point class to represent occupant sensing and status, and (4) new auxiliary properties for occupant interactable equipment to represent the level of controllability for each piece of equipment by occupants. The extension is implemented in the Brick schema and has been tested using multiple occupant datasets from the ASHRAE Global Occupant Database. The extension enables Brick schema to capture diverse types of occupant sensing data and their metadata for FAIR data research and applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Sorting for secreted molecule production using a biosensor-in-microdroplet approach

Significance The design–build–test cycle of metabolic engineering is swiftly becoming test limited owing to advances in DNA synthesis and library design. At the same time, improving extracellular production requires high-throughput studies to detect extracellular (not intracellular) content. Traditional approaches that utilize chromatography-based analysis or plate-based fluorescence assays are relatively throughput limited and require a high degree of liquid handling. These limitations are avoided here by creating a generalizable approach for small molecule production screening. Namely, this paradigm combines “off-the-shelf” biosensors with large library screening from producing cells in a cell-type agnostic manner.

Bowman, Emily K.↗

NASA NTRS2011

Design of a Mechanical NaK Pump for Fission Space Power

Alkali liquid metal cooled fission reactor concepts are under development for spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid, which has specific pumping requirements. Traditionally, electromagnetic linear induction pumps have been used to provide the required flow and pressure head conditions for NaK systems but they can be limited in performance, efficiency, and number of available vendors. The objective of the project was to develop a mechanical NaK centrifugal pump that takes advantages of technology advances not available in previous liquid metal mechanical pump designs. This paper details the design, build, and performance test of a mechanical NaK pump developed at NASA Marshall Space Flight Center. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗

NASA NTRS2016

High-Lift Propeller System Configuration Selection for NASA's SCEPTOR Distributed Electric Propulsion Flight Demonstrator

Although the primary function of propellers is typically to produce thrust, aircraft equipped with distributed electric propulsion (DEP) may utilize propellers whose main purpose is to act as a form of high-lift device. These \high-lift propellers" can be placed upstream of wing such that, when the higher-velocity ow in the propellers' slipstreams interacts with the wing, the lift is increased. This technique is a main design feature of a new NASA advanced design project called Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR). The goal of the SCEPTOR project is design, build, and y a DEP aircraft to demonstrate that such an aircraft can be much more ecient than conventional designs. This paper provides details into the high-lift propeller system con guration selection for the SCEPTOR ight demonstrator. The methods used in the high-lift propeller system conceptual design and the tradeo s considered in selecting the number of propellers are discussed.

Patterson, Michael D.↗

NASA NTRSDate not supplied

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

NASA NTRSDate not supplied

An Optimization-Based Toolchain for Parametric Mechanism Design

Optimization↗

NASA NTRSDate not supplied

Optimization-Based Parametric Design via High-Fidelity Simulation: Overview + Examples

optimization↗

NASA NTRS2006

Adapting Analysis Tools to Engine Externals Analysis

Market forces are driving industry to reproduce product cycle time (the time required to conceive, design, build, test, validate and deliver a product). Application of existing tools in new areas can reduce the time required to design a new product and increase the confidence of acceptable test results later in the expensive testing and validation phase. Finite element methods, computational fluid dynamics codes and sharing of CAD datasets when applied to the design of engine externals can provide methods for product improvement and expedited delivery to the customer.

Dunkelberg, Ken↗

NASA NTRS2008

Root Source Analysis/ValuStream[Trade Mark] - A Methodology for Identifying and Managing Risks

Root Source Analysis (RoSA) is a systems engineering methodology that has been developed at NASA over the past five years. It is designed to reduce costs, schedule, and technical risks by systematically examining critical assumptions and the state of the knowledge needed to bring to fruition the products that satisfy mission-driven requirements, as defined for each element of the Work (or Product) Breakdown Structure (WBS or PBS). This methodology is sometimes referred to as the ValuStream method, as inherent in the process is the linking and prioritizing of uncertainties arising from knowledge shortfalls directly to the customer's mission driven requirements. RoSA and ValuStream are synonymous terms. RoSA is not simply an alternate or improved method for identifying risks. It represents a paradigm shift. The emphasis is placed on identifying very specific knowledge shortfalls and assumptions that are the root sources of the risk (the why), rather than on assessing the WBS product(s) themselves (the what). In so doing RoSA looks forward to anticipate, identify, and prioritize knowledge shortfalls and assumptions that are likely to create significant uncertainties/ risks (as compared to Root Cause Analysis, which is most often used to look back to discover what was not known, or was assumed, that caused the failure). Experience indicates that RoSA, with its primary focus on assumptions and the state of the underlying knowledge needed to define, design, build, verify, and operate the products, can identify critical risks that historically have been missed by the usual approaches (i.e., design review process and classical risk identification methods). Further, the methodology answers four critical questions for decision makers and risk managers: 1. What s been included? 2. What's been left out? 3. How has it been validated? 4. Has the real source of the uncertainty/ risk been identified, i.e., is the perceived problem the real problem? Users of the RoSA methodology have characterized it as a true bottoms up risk assessment.

Brown, Richard Lee↗

DOE OSTI2020

Simulating Buildings While the Design is Still in the Architect's Imagination

Very early in the design process, prior to drawing a single line, architects get information from their client or prospective client trying to understand the nature and requirements of the building that needs to be designed. The design of the building is completely fluid, as the architect considers many options in their imagination. The overall massing of the building, the general shape and form, are being considered during this early step. Even for a simple box-shaped building, the aspect ratio between the east-west and the north-south dimensions of the building can greatly impact energy consumption due to daylighting availability. The prevailing winds and building orientation can impact natural ventilation. The locations of high and low population density spaces can also impact energy use. Deciding the floor area per office workstation or the size of the auditorium will impact energy use. Does making a building two stories instead of one reduce energy impacts by reducing roof area or does the additional volume for stairs and elevators result in more energy use. Since certain types of spaces require more windows for occupants than others, the locations of those spaces will determine how much glazing each building orientation has impacting daylighting as well as heating and cooling energy. The project was an attempted first step toward creating a system tailored toward architects for this very early stage in the design process to help them understand the energy impacts of design options. The approach was not to be based on drawing the building, and instead, the main inputs would have been the size of each type of space in the building. This report describes information gathered during the development that might be of use to others developing similar software as well as some of the software that was developed during the project. Phase II funding to continue this work was not pursued due to intellectual property issues discovered during the development of the commercialization plan.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Next Generation Solid Oxide Fuel Cell Module Development

The overall objective of this project was to develop a transformative Solid Oxide Fuel Cell (SOFC) building block configuration comprised of multi-stack arrays that can be utilized in large-scale power plants. This transformative design signified the benefits of lower performance degradation coupled with improved reliability, low cost, smaller packaging for easier transport and installation, and improved maintenance and field serviceability characteristics. The project goal was to design and fabricate a scalable hot module for housing an array of SOFC stacks and to demonstrate the characteristics of the module gas distribution, insulation and instrumentation, and DC power take-off. The approach was to validate the design of a stack prototype scalable to megawatt (MW) class systems using FuelCell Energy’s Compact SOFC Architecture (CSA) stacks. The scope of work was intended to design, build, and test a compact and low-cost multi-stack sub-module with flexibility to house CSA stacks and scalable to 350 kW which could ultimately be deployed in construction of MW-class systems.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Improving Residential Building Simulations Through Large-Scale Empirical Validation

Residential building energy simulations are increasingly used for energy-efficient building design, codes and standards analysis, home certifications and ratings, utility programs, and technology assessments. Various software tools exist to perform residential building simulations, and these tools often use different models, inputs, and assumptions. This leads to inconsistencies that can undermine confidence in the predicted results. Validation of these tools can increase confidence by ensuring their accuracy and consistency. One way to validate simulation tools is through empirical testing, which compares predicted energy usage to measured utility billing data. This paper describes the process of data collection, data standardization, and empirical validation, and illustrates its use with our residential EnergyPlus (R)-based software. The data and process can be extended to other simulation tools and contribute to improving residential building simulations more broadly.

empirical validation↗