Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “building prototypes”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Limited-constraint WAAM fixture for hybrid manufacturing

This paper describes a limited-constraint alternative to the traditional over-constrained build plate clamping in metal additive manufacturing. A fixture design is presented that enables build plate thermal growth within its plane while restricting deformation perpendicular to that plane. A prototype fixture is designed, fabricated, and tested for wire arc additive manufacturing (WAAM). Experimental results are presented for depositing 1.2 mm diameter 5356 aluminum wire on a 5052 aluminum build plate. The build plate deformation is measured for various clamping torques and a 77.3% reduction in distortion is achieved using the limited-constraint approach with identical WAAM parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Scale Bridging through Active Learning [PowerPoint]

The slides discuss Active Learning and building dynamic surrogate models with confidence with Machine Learning. A prototype example involving mixing and transport in an inertial confinement and fusion experiment illustrates the concept.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

2021 Component Innovation Awardee: Siva Powers America

Siva Powers America earned a Competitiveness Improvement Project (CIP) Component Innovation award that will enable the company to evolve its 250/50 wind turbine design, discontinue its existing 13.4-meter wind turbine blades, and develop new 14.4-meter blades. These longer blades, which have additional extenders at the hub, will increase the rotor diameter to 35 meters, allowing for improved energy production at sites with lower wind resources. A collaboration with the National Renewable Energy Laboratory (NREL) includes a redesign, build, and on-site structural test for the new prototype blades. This will ultimately allow Siva Powers America to pursue recertification of the SIVA 250/50 to meet international standards.

CIP↗
DOE OSTI2026

AutoBEM: A scalable framework for nationwide building energy simulation and retrofit evaluation in the United States

This paper presents AutoBEM, an integrated, automated framework for nationwide building energy modeling and retrofit evaluation in the United States. Unlike prior UBEM platforms that either rely primarily on representative stock sampling or operate at city scale, AutoBEM automates the generation of building-resolved, physics-based EnergyPlus/OpenStudio simulation models at national scale using GIS-derived geometry, prototype-based assumptions, and standardized scalable workflows. Leveraging the Model America dataset and high-performance computing, AutoBEM generates and simulates energy models for 122.9 million buildings, representing 97.8% of the U.S. building stock. These models are being made publicly and freely available as the Model America v1.0 (MAv1) dataset. AutoBEM supports detailed, building-level assessments of energy consumption, CO2 emissions, and post-processed anthropogenic heat emissions (AHE), and evaluates 151 energy conservation measures (ECMs) using localized utility pricing and building characteristics. In addition, AutoBEM incorporates both typical and future climate conditions through integration with Typical Meteorological Year (TMY) and Future TMY (fTMY) weather data derived from IPCC scenarios. In a case study of Phoenix, Arizona, AutoBEM identified several high-efficiency HVAC upgrades and selected envelope measures with short modeled payback periods (1.5 years) for certain building types and standards. Simulations under future climate scenarios (SSP5–RCP8.5) project an 11.3% increase in electricity use and a 32% reduction in natural gas demand by 2100, underscoring the need for climate-adaptive retrofit planning. By enabling reproducible, bottom-up, and location-specific analysis at scale, AutoBEM provides a step toward a national digital twin of the built environment and supports data-driven screening and planning for decarbonization, resilience, and energy equity.

Li, Hang [ORNL] (ORCID:0000000306001920)↗
DOE OSTI2022

Micro-Environmental Control System (Final Report)

This project developed an innovative micro-environmental control system (µX) that enables office buildings to reduce energy used for heating and cooling by 15% or more. The µX is a compact, quiet, and ergonomic device that is designed to be installed under an office workstation; it is designed to maintain occupant comfort when room thermostat setpoints are incremented by 4°F or more (warmer in the summer and cooler in the winter) to save energy. When ambient room temperatures are outside of the usual comfort range, the µX maintains occupant comfort by delivering personalized cooling or heating locally to each office worker. The µX provides personalized cooling using a micro vapor compression system that includes a new high-performance micro-scroll compressor and a novel thermal storage unit. The vapor compression system operates at night to freeze a phase-change material (PCM). During the workday, the cooling stored in the PCM is released as a cool breeze of air to make occupants more comfortable. The micro-scroll compressor was developed specifically for this application; it is smaller than any of its type, minimizing the amount of power needed. In heating mode, the µX maintains occupant comfort using a foot heating mat with an infrared reflective box. The µX R&D project was conducted by Syracuse University in collaboration with United Technologies Research Center, Air Innovations, Bush Technical, and Cornell University. Over the course of the initial three-year project, the team developed and evaluated four versions of the unit, advancing the concept to Technology Readiness Level 6. The capabilities of individual proof-of-concept prototypes were verified in tests that were conducted with: 1) units in psychrometric chambers, 2) an instrumented manikin in a laboratory, and 3) human subjects in laboratories that simulate office environments. The tests verified that the µX prototypes met or exceeded all performance targets required to enable office buildings to reduce energy used for heating and cooling by 15% or more by maintaining occupant comfort when thermostat setpoints are incremented by 4°F or more.

25 ENERGY STORAGE↗
DOE OSTI2022

Understanding Metal–Organic Framework Nucleation from a Solution with Evolving Graphs

A mechanistic understanding of metal–organic framework (MOF) synthesis and scale-up remains underexplored due to the complex nature of the interactions of their building blocks. In this work, we investigate the collective assembly of building units at the early stages of MOF nucleation, using MIL-101(Cr) as a prototypical example. Using large-scale molecular dynamics simulations, we observe that the choice of solvent (water and N,N-dimethylformamide), the introduction of ions (Na+ and F–) and the relative populations of MIL-101(Cr) half-secondary building unit (half-SBU) isomers have a strong influence on the cluster formation process. Additionally, the shape, size, nucleation and growth rates, crystallinity, and short and long-range order largely vary depending on the synthesis conditions. We evaluate these properties as they naturally emerge when interpreting the self-assembly of MOF nuclei as the time evolution of an undirected graph. Solution-induced conformational complexity and ionic concentration have a dramatic effect on the morphology of clusters emerging during assembly. While pure solvents lead to the rapid formation of a small number of large clusters, the presence of ions in aqueous solutions results in smaller clusters and slower nucleation. This diversity is captured by the key features of the graph representation. Principle component analysis on graph properties reveals that only a small number of molecular descriptors is needed to deconvolute MOF self-assembly. Furthermore, descriptors such as the average coordination number between half-SBUs and fractal dimension are of particular interest as they can be can be followed experimentally by techniques like by time-resolved spectroscopy. Ultimately, graph theory emerges as an approach that can be used to understand complex processes revealing molecular descriptors accessible by both simulation and experiment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Investigating relationship between surface topography and emissivity of metallic additively manufactured parts

Due to the direct relationship between thermal history and mechanical behavior, in situ thermal monitoring is key in gauging quality of parts produced with additive manufacturing (AM). Accurate monitoring of temperatures in an AM process requires knowledge of environment and object parameters including object emissivity. The emissivity is dependent on several variables, including: wavelength, material composition, temperature, and surface topography. Researchers have been concerned with the thermal emissivity dependence on temperature since large ranges are seen in metal powder bed processes, but there is also an extensive range of surfaces produced by AM. This work focused on discovering what roughness characteristics control thermal emissivity through investigation of prototypic 316 stainless steel AM samples produced with a range of build conditions on a laser powder bed fusion machine. Through experimental measurements of emissivity using hemispherical directional reflectance (HDR), guided by simulations using a finite-difference time-domain (FDTD) Maxwell solver, it was found that combinations of existing roughness parameters describing both height and slope of the surface correlate well with emissivity changes. Furthermore, these parameters work well due to their apt description of surface features encouraging internal reflection, which is the phenomenon that increases emissivity when a surface falls under the geometric optical region conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Estimating the value of jointly optimized electric power generation and end use: a study of ISO-scale load shaping applied to the residential building stock

A generation-to-load simulation estimated the impact, in terms of production costs and CO2 emissions, attributable to the joint optimization of electric power generation and flexible end uses to support increasing penetrations of renewable energy. Newly conceived, evaluated, and foundational in developing a U.S. National Standard was a transaction-less yet continuous demand response system based on a day-ahead optimum load shape (OLS) designed to encourage Internet-connected devices to autonomously and voluntarily explore options to favour lowest cost generators - without requiring two-way communications, personally identifiable information, or customer opt-in. Boundary conditions used for model calibration included historical weather, residential building stock construction attributes, home appliance and device empirical operating schedules, prototypical power distribution feeder models, thermal generator heat rates, startup and ramping constraints, and fuel costs. Results of an hourly-based annual case study of Texas indicate a 1/3 reduction in production costs and a 1/5 reduction in CO2 emissions are possible.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Progress in ITER ECE diagnostic design and integration

The ITER electron cyclotron emission (ECE) diagnostic system has primary roles in providing measurements of the core electron temperature profile and the electron temperature fluctuation associated with the neoclassical tearing modes. The ITER ECE system includes a radial and oblique line-of-sight. Four 43-meter long low-loss transmission lines (TLs) are designed to transmit millimeter wave power in the frequency range of 70–1000 GHz in both X- and O-mode polarization from the port plug to the ECE instrumentation room in the diagnostic building. The measurement instrumentation includes two Fourier transform spectrometer (FTS) systems and two radiometer systems. The Indian Domestic Agency (IN-DA) and United States Domestic Agency share the responsibility. The IN-DA scope excluding instrumentation and control has passed its preliminary design review and is progressing towards the final design review (FDR). In parallel, the diagnostic integration in different areas is ongoing. Furthermore, several captive components for the TLs have passed FDR and will be manufactured for installation in the tokamak building soon. A peer review meeting has been held on the prototype hot calibration source, and its integration and new thermal analysis in the diagnostic shield module are continuing. A prototype TL is being tested. A prototype polarizing Martin-Puplett type FTS, operating in the frequency range 70–1000 GHz, features an in-vacuo fast scanning mechanism and a cryo-cooled dual-channel THz detector system. Its performance has been assessed in detail against ITER requirements.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

CRADA Number NFE-21-08879 with Hempitecture Inc. (CRADA Final Report)

Participant is a company that was founded on the idea that sustainable materials can help build a better world. These materials can build a better world by preserving our health, saving energy, and storing carbon dioxide. Participant is at a critical juncture where it has significant sales and manufacturing capabilities that can bring innovative, low-carbon, hemp-based building products to market at scale in the United States, but the company has lacked the time and resources to conduct new product development and testing. At Innovation Crossroads, Participant plans to prototype, test, and develop its product roadmap while obtaining necessary performance and impact measurements of its hemp building products for commercialization. Coming into Innovation Crossroads, only one of Participant’s products has commercial sales, HempWool®. Investments are currently being made to add manufacturing capacity in the United States and to provide Participant with the capability to expand its product line throughout the building envelope.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development of Prototypical District-Scale Models

The U.S. has set the climate goal to achieve net-zero greenhouse gas emissions by 2050. District-scale solutions, which include scale-specific opportunities for energy and emissions savings, can be investigated and implemented to help accelerate decarbonization and progress toward this goal. However, there is currently a lack of district-scale models of buildings and community energy systems that can be used to evaluate potential district-scale technologies and strategies across a range of representative community types. This initial work aims to define and develop prototype district models that can be adapted to support the planning, design, and operation of buildings and energy systems in districts considering the complexity and interactions of diverse building loads, weather impacts, distributed energy resources (e.g., PV, EV, electric and thermal energy storage), electric and thermal grid systems, and pricing signals. An overall workflow for developing these prototype district models is established. Stakeholders and potential users of the prototype district models provided technical feedback. The specifications of the selected high priority districts were defined and documented in a scorecard format. An example prototype district model was implemented with the URBANopt platform workflows. A case study was performed to demonstrate the model application.

building energy modeling↗
DOE OSTI2021

Additive Manufacturing in the Nuclear Reactor Industry

This article discusses the application of additive manufacturing in the nuclear reactor industry.Additive manufacturing for nuclear applications increased significantly in the late 2010s due to rapid progress in technology, particularly with methods using metals and ceramics.Because these manufacturing technologies are uniquely data-rich, they allow for an advanced understanding of materials, and they offer the potential to predict part performance based on build data. The inherent characteristics of additive manufacturing technologies allow for rapid prototyping and geometric freedom, making it possible to implement an accelerated agile design process for advanced nuclear reactor applications. Predictive high-fidelity multiphysics simulations are crucial to fully leverage this geometric flexibility. Qualification and regulator acceptance ultimately determine the breadth and scope of applications for these technologies. The US Department of Energy Office of Nuclear Energy Transformational Challenge Reactor program integrates many of these elements to accelerate the deployment of additive manufacturing technologies to industry.

Betzler, Benjamin↗
DOE OSTI2025

Laser system design and critical technologies for the NSF OPAL project

The three-year NSF OPAL project is completing the preliminary design of a 2 x 25-PW all-optical parametric chirped-pulse amplification (OPCPA) system capable of delivering 500-J, 20-fs pulses. The design includes two Alpha beamlines that can be co-timed and pointed into two experimental areas for high-intensity research in several configurations. Additionally, a more flexible 2-PW Beta beam can be used in place of one Alpha beam to allow a wider range of focusing geometries and synchronized electron-beam generation for diverse experimental applications. Here, building on the development of the mid-scale MTW-OPAL prototype system, the NSF OPAL project also focuses on advancing essential technologies, such as large-grating fabrication techniques and actively-cooled disk amplifiers.

42 ENGINEERING↗
DOE OSTI2025

Hydrothermal Growth of Magnetically Frustrated Crystals: Lanthanide Stannate Pyrochlores as a Prototype

One important test bed system for frustrated magnetism is the pyrochlore lattice with the formula A2B2O7 in the cubic space group Fd3(-)m. Both the A and B sites occupy crystallographic trigonal sites and both sites possess a tetrahedral relationship with the other similar metal ion sites. These symmetry relationships generate a 3 D frustrated structure. In frustrated magnetic systems, typically a trivalent lanthanide ion occupies the A site and a magnetically silent tetravalent ion (Ti, Zr, Sn, etc.) occupies the B site. A classical problem related to the crystal growth of these compounds is sample quality. As refractory oxides, the traditional synthesis and crystal growth techniques require high temperatures, which creates two problems that are quite common and endemic to the pyrochlores. One is oxide lattice defects and the other is A/B site disorder. Both issues often occur in the same crystals at the same time and can have a significant impact on the study of physical properties. A hydrothermal approach can be applied to this problem. The relatively low crystal growth temperatures (600-720˚C) greatly minimize nonstoichiometry, lattice defects and A/B site disorder. The reduction of these pervasive imperfections significantly increases the quality of the observed physical property data. This talk will focus on the lanthanide stannates Ln2Sn2O7 as a prototype test bed of these systems. The stannates are among the few building blocks that can stabilize the pyrochlore structure type for all the lanthanides and they serve as an excellent proving ground for a wide range of physical properties. The synthesis and crystal growth of the lanthanide stannates will be reviewed, along with a discussion of some of the physical properties that result from the frustrated magnetic states of these low defect crystals.

Hydrothermal, crystal growth↗
DOE OSTI2021

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗
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 OSTI2023

Development of Prototypical District-Scale Models: Preprint

The U.S. has set the climate goal to achieve net-zero greenhouse gas emissions by 2050. District-scale solutions, which include scale-specific opportunities for energy and emissions savings, can be investigated and implemented to help accelerate decarbonization and progress toward this goal. However, there is currently a lack of district-scale models of buildings and community energy systems that can be used to evaluate potential district-scale technologies and strategies across a range of representative community types. This initial work aims to define and develop prototype district models that can be adapted to support the planning, design, and operation of buildings and energy systems in districts considering the complexity and interactions of diverse building loads, weather impacts, distributed energy resources (e.g., PV, EV, electric and thermal energy storage), electric and thermal grid systems, and pricing signals. An overall workflow for developing these prototype district models is established. Stakeholders and potential users of the prototype district models provided technical feedback. The specifications of the selected high priority districts were defined and documented in a scorecard format. An example prototype district model was implemented with the URBANoptTM platform workflows. A case study was performed to demonstrate the model application.

district↗
DOE OSTI2022

Charge Delocalization and Vibronic Couplings in Quadrupolar Squaraine Dyes

Squaraines are prototypical quadrupolar charge-transfer chromophores that have recently attracted much attention as building blocks for solution-processed photovoltaics, fluorescent probes with large two-photon absorption cross sections, and aggregates with large circular dichroism. Their optical properties are often rationalized in terms of phenomenological essential state models, considering the coupling of two zwitterionic excited states to a neutral ground state. As a result, optical transitions to the lowest S 1 excited state are one-photon allowed, whereas the next higher S 2 state can only be accessed by two-photon transitions. A further implication of these models is a substantial reduction of vibronic coupling to the ubiquitous high-frequency vinyl-stretching modes of organic materials. Here, in this study, we combine time-resolved vibrational spectroscopy, two-dimensional electronic spectroscopy, and quantum-chemical simulations to test and rationalize these predictions for nonaggregated molecules. We find small Huang–Rhys factors below 0.01 for the high-frequency, 1500 cm –1 modes in particular, as well as a noticeable reduction for those of lower frequency modes in general for the electronic S 0 → S 1 transition. The two-photon allowed state S 2 is well separated energetically from S 1 and has weak vibronic signatures as well. Thus, the resulting pronounced concentration of the oscillator strength in a narrow region relevant to the lowest electronic transition makes squaraines and their aggregates exceptionally interesting for strong and ultrastrong coupling of excitons to localized light modes in external resonators with chiral properties that can largely be controlled by the molecular architecture.

36 MATERIALS SCIENCE↗