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DOE OSTI2021

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1975

The Deep Space Network

This report presents DSN progress in flight project support, tracking and data acquisition (TDA) research and technology, network engineering, hardware and software implementation, and operations. Each issue presents material in some, but not all, of the following categories in the order indicated. - Description of the DSN - Mission Support Ongoing Planetary/Interplanetary Flight Projects Advanced Flight Projects - Radio Science - Special Projects - Supporting Research and Technology Tracking and Ground-Based Navigation Communications--Spacecraft/Ground Station Control and Operations Technology Network Control and Data Processing - Network and Facility Engineering and Implementation Network Network Operations Control Center Ground Communications Deep Space Stations - Operations Network Operations Network Operations Control Center Ground Communications Deep Space Stations - Program Planning TDA Planning Quality Assurance In each issue, the part entitled "Description of the DSN" describes the functions and facilities of the DSN and may report the current configuration of one of the five DSN systems (Tracking, Telemetry, Command, Monitor & Control, and Test & Training). The work described in this report series is either performed or managed by the Tracking and Data Acquisition organization of JPL for NASA.

Tracking and Data Acquisition organization↗

DOE OSTI2024

Project DarkStar: Vision for LLNL in 2030

DarkStar was a Strategic Initiative (FY2021-FY2024) to investigate applications of Artificial Intelligence (AI) and Machine Learning (ML) to scientific problems of complex hydrodynamics, shockwave physics and energetic materials. The research focused on physics and engineering design as a process that can be tremendously accelerated through merging AI with advanced physics simulation on exascale-class platforms, and to experimentally validate this revolutionary new approach through dynamic materials campaigns. A central thread of scientific inquiry was in the application of AI to enable human understanding of how to control hydrodynamic instability (which has impacts to areas such as inertial confinement fusion) via engineering features and time-dependent sources. Motivated by an unfinished line of research started by Dr. Johnny von Neumann, AI-enabled simulation approaches were developed that allowed DarkStar researchers to uncover several ground-breaking discoveries regarding hydrodynamic instability, including how to completely suppress Richtmyer-Meshkov instability (RMI). These S&T discoveries, along with other advances, have shown the way for an entirely new approach to time-dependent problems known as inverse design – the idea that complex systems can be developed directly from a final state that is to be achieved and resolve the initial design via satisfying several constraints simultaneously via AI/ML. Through experimental campaigns conducted across a wide range of facilities in the NNSA complex (the High Explosive Application Facility at LLNL, the Dynamic Compression Sector/Advanced Photon Source at Argonne National Lab, and Special Technologies Laboratory at MSTS) the radical new AI/ML approach to engineering complex material dynamics was verified, establishing a new field of study within the realm of shock physics. As advanced manufacturing capabilities continue to develop, the great importance of inverse design as a means to apply that technology effectively for NNSA missions will feature prominently over this decade. DarkStar has positioned NNSA as a world-leader in this newly emerging cross-disciplinary area of AI methods for advanced physics simulation and pioneered multiple novel approaches that have enabled the broader scientific community. By allowing us to see past the horizon, to 2030 and beyond, DarkStar has illuminated the vast potential of AI/ML to impact a wide range of new national security missions and, consequently, multiple areas of further research have already emerged across the NNSA and DOD complex.

42 ENGINEERING↗

DOE OSTI2023

Accelerating Manufacturing of Powder-Processed Strong, Lightweight and Thermally Stable Bulk Nanocrystalline Al Alloys via Engineered Interface States

The overarching goal of this program is to develop an integrated materials by design framework enabling a simple, scalable, and efficient manufacturing route for thermally stable nanocrystalline Al-based alloys with high specific strength over a range of service temperatures. The central scientific principle underpinning this program is the elucidation, and ultimately implementation in novel alloy design, of unique interfacial structures and chemistries driven by segregation in multi-component systems that give rise to unprecedented processability and properties. This program targeted nanocrystalline Al-based ternary alloys produced by mechanical alloying of powders followed by compaction and sintering with hot pressing, which are inherently scalable and inexpensive manufacturing routes, but when applied to nanocrystalline alloys are usually plagued by low density and/or poor retention of the intended nanostructures during processing. This program successfully demonstrated manufacturing of a bulk (>1 cm 3 ) nanocrystalline Al-based alloy with a combination of thermal stability, high temperature strength retention, and specific strength that exceeds the current-state-of-the-art of Al alloys. It is anticipated that the greatest technological impact will occur by demonstration of rapid and scalable manufacturing of bulk nanocrystalline Al alloys with exceptional thermal stability and mechanical performance, thus enabling increased energy efficiency in high performance power generation systems via: (i) replacement of existing components with lightweight Al-based alloys and (ii) increasing operating temperatures with property retention. The program focused on the development of a simple and efficient manufacturing route for thermally stable nanocrystalline Al-based alloys with high specific strength over a range of service temperatures. The program is expected to have direct impact on scalable and economic manufacturing of bulk nanocrystalline alloys. This program profited from the recent discovery by the project team of segregation-driven amorphous intergranular films in nanocrystalline metallic alloys that can be kinetically frozen-in at sub-solidus temperatures. These interfacial states (also known as amorphous complexions) comprise a large fraction of the total material in nanocrystalline alloys and are responsible for two beneficial characteristics that anchor the proposed work: (1) activated sintering leading to high density and (2) retained nanostructures leading to high strengths that approach a substantial fraction of the theoretical limit. More specifically, these engineered interfaces led to a three-fold benefit: (i) high-throughput materials processing with low energy budget and cost, (ii) exceptional thermal stability, and (iii) high specific strength at both room temperature and intermediate temperatures experienced during service.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Reverse engineering nuclear properties from rare earth abundances in the r process

The bulk of the rare earth elements are believed to be synthesized in the rapid neutron capture process or r process of nucleosynthesis. The solar r-process residuals show a small peak in the rare earths around $A\sim 160$, which is proposed to be formed dynamically during the end phase of the r process by a pileup of material. This abundance feature is of particular importance as it is sensitive to both the nuclear physics inputs and the astrophysical conditions of the main r process. Here, we explore the formation of the rare earth peak from the perspective of an inverse problem, using Monte Carlo studies of nuclear masses to investigate the unknown nuclear properties required to best match rare earth abundance sector of the solar isotopic residuals. When nuclear masses are changed, we recalculate the relevant β-decay properties and neutron capture rates in the rare earth region. The feedback provided by this observational constraint allows for the reverse engineering of nuclear properties far from stability where no experimental information exists. We investigate a range of astrophysical conditions with this method and show how these lead to different predictions in the nuclear properties influential to the formation of the rare earth peak. Finally, we conclude that targeted experimental campaigns in this region will help to resolve the type of conditions responsible for the production of the rare earth nuclei, and will provide new insights into the longstanding problem of the astrophysical site(s) of the r process.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1995

Use of agents to implement an integrated computing environment

Integrated Product and Process Development (IPPD) embodies the simultaneous application to both system and quality engineering methods throughout an iterative design process. The use of IPPD results in the time-conscious, cost-saving development of engineering systems. To implement IPPD, a Decision-Based Design perspective is encapsulated in an approach that focuses on the role of the human designer in product development. The approach has two parts and is outlined in this paper. First, an architecture, called DREAMS, is being developed that facilitates design from a decision-based perspective. Second, a supporting computing infrastructure, called IMAGE, is being designed. Agents are used to implement the overall infrastructure on the computer. Successful agent utilization requires that they be made of three components: the resource, the model, and the wrap. Current work is focused on the development of generalized agent schemes and associated demonstration projects. When in place, the technology independent computing infrastructure will aid the designer in systematically generating knowledge used to facilitate decision-making.

Hale, Mark A.↗

NASA NTRS2007

Rapid Engineering of Three-Dimensional, Multicellular Tissues With Polymeric Scaffolds

A process has been developed for the rapid tissue engineering of multicellular-tissue-equivalent assemblies by the controlled enzymatic degradation of polymeric beads in a low-fluid-shear bioreactor. In this process, the porous polymeric beads serve as temporary scaffolds to support the assemblies of cells in a tissuelike 3D configuration during the critical initial growth phases of attachment of anchorage-dependent cells, aggregation of the cells, and formation of a 3D extracellular matrix. Once the cells are assembled into a 3D array and enmeshed in a structural supportive 3D extracellular matrix (ECM), the polymeric scaffolds can be degraded in the low-fluid-shear environment of the NASA-designed bioreactor. The natural 3D tissuelike assembly, devoid of any artificial support structure, is maintained in the low-shear bioreactor environment by the newly formed natural cellular/ECM. The elimination of the artificial scaffold allows normal tissue structure and function.

Gonda, Steve R.↗

DOE OSTI2015

Upscaling ab-initio chemistry models to non-equilibrium flow simulations

Thermochemical nonequilibrium is generated by hypersonic cruise vehicles, high speed combustion and detonations. Nonequilibrium interactions affect reaction rates and energy transfer that are critical for many engineering applications. Ab-initio potential energy surfaces can be used in quasi-classical trajectory (QCT) calculations to calculate state-specific dissociation rates and cross sections, as well as state-to-state energy exchange rates and cross sections. These rates and cross sections are needed for simulating such nonequilibrium flows. However, there are two main challenges in extending QCT calculations to modeling all chemical processes found in typical engineering flowfields. First, ab-initio surfaces for many collision partners are not available and when available their fidelity is not quantified. Second, state-to-state cross section datasets are typically on the order of 1000 4, , and are too large to be efficiently implemented in engineering simulations. This work focuses on O 2 +O interactions because of prevalence of oxygen in many engineering application; however, all of the models developed here may be applied to other diatom-atom interactions and can be extended to other diatom-diatom combinations. It is shown in this work that at temperatures between 2,500 and 20,000K, state-specific cross sections are not highly sensitive to potentials and a Morse additive pairwise (MAP) potential is proposed for modeling collisions for which ab-initio potentials are not available. Next, this work suggests an approach to model state-to-state cross sections based on maximum entropy considerations. The calculated cross sections are fit to a new model with just 8 parameters, which can be easily scaled up to flow simulations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Integrated Flue Gas Purification and Latent Heat Recovery for Pressurized Oxy-Combustion (Final Scientific/Technical Report)

Pressurized oxy-combustion has been identified by DOE as a transformational technology for coal power with carbon capture due to the advantages that are realized when the combustion process is pressurized. The staged pressurized oxy-combustion (SPOC) process is particularly attractive as the efficiency of the process is almost 6 percentage points greater than that of first generation oxy-combustion. A critical component of the SPOC process, and potentially other pressurized combustion processes, is the Direct Contact Cooler (DCC) where the latent heat of the flue gas moisture is recovery to improve plant efficiency while simultaneously removing SO x and NO x from the flue gas, so that the FGD and de-NO x processes can be eliminated, and the cost of electricity minimized. The objective of this R&D effort was to advance the TRL of the DCC technology, which included performance testing at a 100 kW scale to validate the process and obtain key engineering data for scale-up. A collateral objective was to study the gas- and liquid-phase kinetics, and the development of a systematic chemical mechanism validated by experimental data. Experiments in a bench-scale stirred reactor provided an updated understanding of the liquid chemistry and the effects of temperature and pH. This information was used to develop a reduced reaction mechanism, which was subsequently incorporated in an ASPENbased process model, to allow for evaluation of the DCC at full scale. A small-pilot DCC column was designed, constructed and tested using simulated flue gas at the pressurized oxy-combustion test facility at Washington University in St. Louis. In the majority of tests, the SO 2 capture approached 100%, making the NO x capture the primary metric of capture efficiency. An NO x capture efficiency of 90% was achieved when the gas residence time was 95 seconds, demonstrating that high capture rates can be attained with reasonable reactor size. At higher temperatures (up to 200°C inlet gas temperature) the total NO x scrubbing efficiency was reduced by approximately 10% (compared to room temp.) and this was attributed to a reduced NO oxidation rate. A significant amount of SO 2 was present in the gas outlet (10%) only when the temperature was high and the N:S ratio was low (N/S < 1), which highlights the necessity of controlling the NOx concentration in the flue gas for complete sulfur scrubbing. After incorporated our optimized chemical mechanism into an ASPEN process model, various full-scale configurations of the DCC were evaluate, and the results indicate that the proposed DCC can accomplish its intended goals at full scale and at a modest size. Thus, the results of this project indicate that the DCC is a promising technology for recovery of the latent heat of the moisture in the flue gas while simultaneously scrubbing the nitrogen and sulfur oxides, thus enabling pressurized oxy-combustion, in general, and the SPOC process, in particular.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Achieving high rate performance in hybrid pristine-recycled cathodes using model-informed electrode designs

Direct recycling lithium-ion battery cathodes, a process that retains the engineered oxide structures from end-of-life materials, presents a cost-effective and energy-efficient alternative to other battery recycling methods. However, while direct-recycled cathodes have demonstrated performance comparable to that of pristine materials at low cycling rates, their high-rate performance remains uncertain. Morphology changes in cathode particles, a main mode of degradation, directly impact rate performance by limiting surface kinetics and solid-phase diffusion. If direct recycling processes do not sufficiently restore pristine-like morphologies, the recycled materials may retain structural defects that hinder high-rate performance. The present work uses a physics-based pseudo-2D model to simulate hybrid electrodes with pristine and artificially “aged/recycled” NMC materials to investigate potential impacts of incorporating performance-limited aged cathode materials into cells. The study highlights how differences in transport and kinetic properties can influence rate capabilities in mixed electrodes — particularly in high-loading cells in high-demand applications. However, model results also reveal a possible mitigation strategy via dual-layer electrode architectures with lower-performing materials positioned near the current collector. Simulations of 4.0 mAh cm −2 cells cycled at 4C using a dual-layer architecture provided approximately 5%–30% more capacity in constant-current protocols compared to homogeneously blended electrode architectures with the same loadings and mixed-material compositions. These findings highlight the importance of strategic electrode design in minimizing potential performance losses and facilitating the integration of recycled materials into high-performance batteries, advancing sustainable and cost-effective battery manufacturing.

25 ENERGY STORAGE↗

DOE OSTI2018

ICME Guided Development of Advanced Cast Aluminum Alloys for Automotive Engine Applications (ADAPA)

Project Objectives: To develop a new class of advanced, cost competitive aluminum casting alloys providing a 25% improvement in component strength relative to components made with A319 or A356 alloys using sand and semi-permanent casting processes for high-performance engine applications. To demonstrate the power of Integrated Computational Materials Engineering (ICME) tools for accelerating the development of new materials and processing techniques, as well as to identify the gaps in ICME capabilities. To develop comprehensive cost models to ensure that components manufactured with these new alloys do not exceed 110% of the cost using incumbents alloys A319 or A356. To develop a technology transfer and commercialization plan for deployment of these new alloys in automotive engine applications. The key targets and baseline are shown in the table below.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Open Building Control

Best practice control sequences are often not implemented correctly, or are not implemented at all, in large commercial buildings. This typically leads to 10-30 percent energy waste, along with reduced occupant productivity and unnecessary equipment wear. The current process of designing and implementing such control sequences is a manual process that starts with designers who often don’t have adequate training, then requires controls programmers to interpret and program a verbose written sequence. This process has been shown to fail to deliver high performance control sequences at scale. The Open Building Control project digitizes the current control delivery process. The project is developing tools for system designers to select control sequences, assess their energy performance and load flexibility potential using whole building simulation, specify the sequence for implementation using machine-to-machine translation by a control provider and formally testing the as-installed sequences by a commissioning agent. The project developed tools for each stage of this delivery process. The key innovation of the project is the development of the Control Description Language, a language that allows such a digitized control delivery process with end-to-end verification. Libraries of control sequences have been implemented using the Control Description Language, and their performance has been demonstrated using whole building energy simulation. An automated translation of such sequences to a commercial control product line has been conducted using a prototype translator. Tools for formal verification of as-installed control sequences relative to their specification have been developed and demonstrated. The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) started the process of forming a committee to make this language an ASHRAE/ANSI Standard. This new standard will complement existing and emerging ASHRAE standards for building communication and semantic modeling by providing a standard for expressing the control logic - the actual brain of the building. We expect this language and the process it enables to be an important contribution to the deployment of high performance building control sequences at scale because it allows taming the complexity of the control delivery process, which is continually increasing due to the need for higher performance and increased load flexibility to meet goals for net zero energy and increased renewable integration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

MBSE Execution of Scalable Autonomous Operations for a High Density Vertiplex

The High Density Vertiplex (HDV) subproject of NASA’s Advanced Air Mobility (AAM) project adopted Model-Based Systems Engineering (MBSE) and NASA SE processes were executed via MBSE using MagicDraw. Since the adoption of MBSE and utilization of MagicDraw, the systems engineering team has made tremendous strides in each pillar of MBSE including, requirements, behavior, and structure. Scalable Autonomous Operations (SAO) was a stage in the development of the High Density Vertiplex focusing on the autonomous terminal operations of a vertiport with sUAS aircraft. MBSE served the systems engineering team to document and verify the physical architecture and capture a logical architecture of SAO for distribution to the AAM community. This paper will detail methodologies that were created to successfully execute NASA SE processes via MBSE in the SAO stage as well as highlight challenges and lessons learned.

Demetrios Katsaduros↗

NASA NTRS1993

Modernization of the NASA scientific and technical information program

The NASA Scientific and Technical Information Program utilizes a technology infrastructure assembled in the mid 1960s to late 1970s to process and disseminate its information products. When this infrastructure was developed it placed NASA as a leader in processing STI. The retrieval engine for the STI database was the first of its kind and was used as the basis for developing commercial, other U.S., and foreign government agency retrieval systems. Due to the combination of changes in user requirements and the tremendous increase in technological capabilities readily available in the marketplace, this infrastructure is no longer the most cost-effective or efficient methodology available. Consequently, the NASA STI Program is pursuing a modernization effort that applies new technology to current processes to provide near-term benefits to the user. In conjunction with this activity, we are developing a long-term modernization strategy designed to transition the Program to a multimedia, global 'library without walls.' Critical pieces of the long-term strategy include streamlining access to sources of STI by using advances in computer networking and graphical user interfaces; creating and disseminating technical information in various electronic media including optical disks, video, and full text; and establishing a Technology Focus Group to maintain a current awareness of emerging technology and to plan for the future.

Cotter, Gladys A.↗

NASA NTRS2002

Comparisons of Kinematics and Dynamics Simulation Software Tools

Kinematic and dynamic analyses for moving bodies are essential to system engineers and designers in the process of design and validations. 3D visualization and motion simulation plus finite element analysis (FEA) give engineers a better way to present ideas and results. Marshall Space Flight Center (MSFC) system engineering researchers are currently using IGRIP from DELMIA Inc. as a kinematic simulation tool for discrete bodies motion simulations. Although IGRIP is an excellent tool for kinematic simulation with some dynamic analysis capabilities in robotic control, explorations of other alternatives with more powerful dynamic analysis and FEA capabilities are necessary. Kinematics analysis will only examine the displacement, velocity, and acceleration of the mechanism without considering effects from masses of components. With dynamic analysis and FEA, effects such as the forces or torques at the joint due to mass and inertia of components can be identified. With keen market competition, ALGOR Mechanical Event Simulation (MES), MSC visualNastran 4D, Unigraphics Motion+, and Pro/MECHANICA were chosen for explorations. In this study, comparisons between software tools were presented in terms of following categories: graphical user interface (GUI), import capability, tutorial availability, ease of use, kinematic simulation capability, dynamic simulation capability, FEA capability, graphical output, technical support, and cost. Propulsion Test Article (PTA) with Fastrac engine model exported from IGRIP and an office chair mechanism were used as examples for simulations.

Yeu-Sheng Paul Shiue↗

NASA NTRS1994

Ordering design tasks based on coupling strengths

The design process associated with large engineering systems requires an initial decomposition of the complex system into modules of design tasks which are coupled through the transference of output data. In analyzing or optimizing such a coupled system, it is essential to be able to determine which interactions figure prominently enough to significantly affect the accuracy of the system solution. Many decomposition approaches assume the capability is available to determine what design tasks and interactions exist and what order of execution will be imposed during the analysis process. Unfortunately, this is often a complex problem and beyond the capabilities of a human design manager. A new feature for DeMAID (Design Manager's Aid for Intelligent Decomposition) will allow the design manager to use coupling strength information to find a proper sequence for ordering the design tasks. In addition, these coupling strengths aid in deciding if certain tasks or couplings could be removed (or temporarily suspended) from consideration to achieve computational savings without a significant loss of system accuracy. New rules are presented and two small test cases are used to show the effects of using coupling strengths in this manner.

Rogers, James L., Jr.↗

NASA NTRS1994

Ordering Design Tasks Based on Coupling Strengths

Rogers, J. L.↗

NASA NTRS2010

GLobal Integrated Design Environment (GLIDE): A Concurrent Engineering Application

The GLobal Integrated Design Environment (GLIDE) is a client-server software application purpose-built to mitigate issues associated with real time data sharing in concurrent engineering environments and to facilitate discipline-to-discipline interaction between multiple engineers and researchers. GLIDE is implemented in multiple programming languages utilizing standardized web protocols to enable secure parameter data sharing between engineers and researchers across the Internet in closed and/or widely distributed working environments. A well defined, HyperText Transfer Protocol (HTTP) based Application Programming Interface (API) to the GLIDE client/server environment enables users to interact with GLIDE, and each other, within common and familiar tools. One such common tool, Microsoft Excel (Microsoft Corporation), paired with its add-in API for GLIDE, is discussed in this paper. The top-level examples given demonstrate how this interface improves the efficiency of the design process of a concurrent engineering study while reducing potential errors associated with manually sharing information between study participants.

McGuire, Melissa L.↗

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