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

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Experiences with serial and parallel algorithms for channel routing using simulated annealing

Two algorithms for channel routing using simulated annealing are presented. Simulated annealing is an optimization methodology which allows the solution process to back up out of local minima that may be encountered by inappropriate selections. By properly controlling the annealing process, it is very likely that the optimal solution to an NP-complete problem such as channel routing may be found. The algorithm presented proposes very relaxed restrictions on the types of allowable transformations, including overlapping nets. By freeing that restriction and controlling overlap situations with an appropriate cost function, the algorithm becomes very flexible and can be applied to many extensions of channel routing. The selection of the transformation utilizes a number of heuristics, still retaining the pseudorandom nature of simulated annealing. The algorithm was implemented as a serial program for a workstation, and a parallel program designed for a hypercube computer. The details of the serial implementation are presented, including many of the heuristics used and some of the resulting solutions.

Brouwer, Randall Jay↗
DOE OSTI2023

Enabling control co-design of the next generation of wind power plants

Abstract. Layout design and wake steering through wind plant control are important and complex components in the design and operation of modern wind power plants. They are currently optimized separately, but with more and more computational and experimental studies demonstrating the gains possible through wake steering, there is a growing need from industry and regulating bodies to combine the layout and control optimization in a co-design process. However, combining these two optimization problems is currently infeasible due to the excessive number of design variables and large solution space. In this article, we present a method that enables the coupled optimization of wind power plant layout and wake steering with no additional computational expense than a traditional layout optimization. We developed a geometric relationship between wind turbines to find an approximate optimal yaw angle, bypassing the need for either a nested or coupled wind plant control optimization. It also provides a significant and immediate improvement to wind power plant design by enabling the co-design of turbine layout and yaw control for wake steering. A small co-designed plant shown in this article produces 0.8 % more energy than its sequentially designed counterpart. This additional energy production comes with no additional infrastructure, turbine hardware, or control software; it is simply the outcome of optimizing the turbine layout and yaw control together, resulting in millions of dollars of additional revenue for the wind power plants of the future.

17 WIND ENERGY↗
NASA NTRS1993

Firmware Development Improves System Efficiency

Most manufacturing processes require physical pointwise positioning of the components or tools from one location to another. Typical mechanical systems utilize either stop-and-go or fixed feed-rate procession to accomplish the task. The first approach achieves positional accuracy but prolongs overall time and increases wear on the mechanical system. The second approach sustains the throughput but compromises positional accuracy. A computer firmware approach has been developed to optimize this point wise mechanism by utilizing programmable interrupt controls to synchronize engineering processes 'on the fly'. This principle has been implemented in an eddy current imaging system to demonstrate the improvement. Software programs were developed that enable a mechanical controller card to transmit interrupts to a system controller as a trigger signal to initiate an eddy current data acquisition routine. The advantages are: (1) optimized manufacturing processes, (2) increased throughput of the system, (3) improved positional accuracy, and (4) reduced wear and tear on the mechanical system.

Chern, E. James↗
NASA NTRS1977

Information distribution in distributed microprocessor based flight control systems

This paper presents an optimal control theory that accounts for variable time intervals in the information distribution to control effectors in a distributed microprocessor based flight control system. The theory is developed using a linear process model for the aircraft dynamics and the information distribution process is modeled as a variable time increment process where, at the time that information is supplied to the control effectors, the control effectors know the time of the next information update only in a stochastic sense. An optimal control problem is formulated and solved that provides the control law that minimizes the expected value of a quadratic cost function. An example is presented where the theory is applied to the control of the longitudinal motions of the F8-DFBW aircraft. Theoretical and simulation results indicate that, for the example problem, the optimal cost obtained using a variable time increment Markov information update process where the control effectors know only the past information update intervals and the Markov transition mechanism is almost identical to that obtained using a known uniform information update interval.

Montgomery, R. C.↗
DOE OSTI2022

Dynamic optimization with flexible heat integration of a solar parabolic trough collector plant with thermal energy storage used for industrial process heat

There is an increasing need to reduce fossil fuel consumption used for industrial process heat to slow the effects of climate change. Using solar thermal heat is a viable way to replace fossil fuel use, but solar industrial process heat plants have limited implementation due to large upfront costs and inefficiencies from the inherent variability from solar energy. Having more flexible and optimized control over these plants can enable them to be more efficient. Here in this work, a solar industrial process heat plant with thermal energy storage that can flexibly collect and deliver heat to two industrial processes (flexible heat integration) is dynamically modeled with control setpoints found by a dynamic optimization method. The optimized case can increase the solar efficiency of the plant by 7.5% on average relative to a base case. The results show that it is best to collect heat at lower temperatures for all but ideal solar conditions, only medium to high quality heat should be stored in large quantities, and exchanging heat with a lower temperature heat sink is generally more efficient. The optimized case is able to reduce the levelized cost of heat of the plant to $31.83/MWh th compared to a base case value of $34.10/MWh th . The optimized case can reduce emissions by 22.2% compared to a plant which uses only natural gas. This work shows that dynamic optimization with flexible heat integration can be a cost-effective way to increase efficiency so that more of these types of plants can be implemented.

14 SOLAR ENERGY↗
NASA NTRS1985

Using a life-cycle-cost criterion for multi-disciplinary design studies for the Manned Space Station

A life-cycle-cost measure for the Manned Space Station is suggested which considers the mass, initial cost, aerodynamic drag, electrical power, moment, required ground support, and expected life of subsystems or components. It is proposed that this life-cycle-cost measure be considered as a criterion for design trade-off studies involving controls and structures. Calculating the related sensitivities in the optimization process is discussed and then applied to specific examples. In the first example, the reaction control system is analyzed with regard to the design of its supporting structure and selection of rocket type. Values of support beam length, structural material selection, and rocket propellant selection are determined which minimize life-cycle-cost. In the second example, the alignment of solar arrays are analyzed for efficiency with regard to generating power, their drag, and their aerodynamic moment. Alignment angles are determined which again minimize life cycle cost. It seems clear from these and other examples that the proposed criterion has value for multi-disciplinary design studies for the Manned Space Station.

Taylor, L. W.↗
DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines: Preprint

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be timeconsuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the towerbase damage equivalent loading and better tracking of the rated generator speed and power.

closed-loop control↗
DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be time-consuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the tower-base damage equivalent loading and better tracking of the rated generator speed and power.

axial flow↗
DOE OSTI2026

Formulation and Performance Evaluation of Epoxy Sealant Systems for Double-Shell Tank Bottom Refurbishment

The performance of epoxy sealants used in the refurbishment of double-shell tank (DST) systems requires balancing processability, thermomechanical stability, and adhesion to cementitious substrates. This study incorporates Heloxy 8 as a reactive diluent into Westlake 862 epoxy to tailor workability and cured-state properties. Rheological time-sweep analysis demonstrates that increasing the diluent content significantly reduces complex viscosity and extends workability, thereby improving pumpability and flow for large-area applications. However, the targeted 2-hour processing window is not fully achieved. Differential scanning calorimetry (DSC) confirms that all formulations cure at room temperature to glass transition temperatures ( T g ) at least 20 °C above the maximum DST operating temperature (27 °C), thereby ensuring service in the glassy regime. Dynamic mechanical analysis (DMA) reveals formulation-dependent reductions in tan delta and increases in storage modulus, indicating increasingly elastic and mechanically stable networks with diluent incorporation. Pull-off adhesion testing shows that modified formulations (70–90% Westlake epoxy) exhibit significantly higher adhesion strengths than the unmodified system. Grout cohesive failure indicates that interfacial bonding exceeds substrate strength. Collectively, these results demonstrate that controlled reactive diluent incorporation enables optimization of processing behavior, interfacial adhesion, and thermomechanical performance, supporting the suitability of the modified epoxy systems as durable sealant layers for cementitious barrier applications in hazardous waste containment infrastructure.

Differential scanning calorimetry↗
DOE OSTI2022

Dissipation and Bathymetric Sensitivities in an Unstructured Mesh Global Tidal Model

Abstract The mechanisms and geographic distribution of global tidal dissipation in barotropic tidal models are examined using a high resolution unstructured mesh finite element model. Mesh resolution varies between 2 and 25 km and is especially focused on inner shelves and steep bathymetric gradients. Tidal response sensitivities to bathymetric changes are examined to put into context response sensitivities to frictional processes. We confirm that the Ronne Ice Shelf dramatically affects Atlantic tides but also find that bathymetry in the Hudson Bay system is a critical control. We follow a sequential frictional parameter optimization process and use TPXO9 data‐assimilated tidal elevations as a reference solution. From simulated velocities and depths, dissipation within the global model is estimated and allows us to pinpoint dissipation at high resolution. Boundary layer dissipation is extremely focused with 1.4% of the ocean accounting for 90% of the total. Internal tide friction is much more distributed with 16.7% of the ocean accounting for 90% of the total. Often highly regional dissipation can impact basin‐scale and even ocean wide tides. Optimized boundary layer friction parameters correlate very well with the physical characteristics of the locality with high friction factors associated with energetic tidal regions, deep ocean island chains, and ice covered areas. Global complex M 2 tide errors are 1.94 cm in deep waters. Total global boundary layer and internal tide dissipation are estimated, respectively, at 1.83 and 1.49 TW. This continues the trend in the literature toward attributing more dissipation to internal tides.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
NASA NTRS1998

Numerical Simulations of a Lobed Fuel Injector

Numerical modeling of the nonreactive mixing processes associated with a lobed fuel injector in a coflowing air stream is presented. The lobed fuel injector is a device which generates strong streamwise vorticity, producing locally high strain rates which can enhance the molecular mixing of reactants while delaying ignition in a controlled manner. Vortex element modeling is used to simulate flow field evolution and fuel element mixing characteristics for this lobed fuel injector. Quantitative predictions for vorticity generation and qualitative results for streamwise rollup compare well qualitatively with recent experimental investigations of this flow field [Smith et al, Phys. Fluids 9, 667 (1997)]. Parametric studies of the effects of lobe amplitude-to-wavelength ratio, lobe angle, and lobe shape for given flow conditions suggest that geometrical features may be optimized to enhance mixing and control reaction processes.

Strickland, J. H.↗
NASA NTRS1977

Image data-processing system for solar astronomy

The paper describes an image data processing system (IDAPS), its hardware/software configuration, and interactive and batch modes of operation for the analysis of the Skylab/Apollo Telescope Mount S056 X-Ray Telescope experiment data. Interactive IDAPS is primarily designed to provide on-line interactive user control of image processing operations for image familiarization, sequence and parameter optimization, and selective feature extraction and analysis. Batch IDAPS follows the normal conventions of card control and data input and output, and is best suited where the desired parameters and sequence of operations are known and when long image-processing times are required. Particular attention is given to the way in which this system has been used in solar astronomy and other investigations. Some recent results obtained by means of IDAPS are presented.

Wilson, R. M.↗
NASA NTRS1974

A unified approach to aircraft parameter identification

The most accurate identification results are obtained when all three elements of the identification process - the identification algorithm, the control input, and the instrumentation system - are considered in a unified approach. This type of approach for the design of optimal control inputs and for determining the effect of the instrumentation system, in each case with respect to the identification process is discussed. Design of control inputs which optimize the sensitivity of the system output to the unknown parameters is given. Results using these inputs in an extensive simulation of the identification process indicate they perform measurably better than doublet type inputs. A technique is then presented for specifying an optimal instrumentation system or for determining the effect, the instrumentation system has on the accuracy of the parameter estimates.

Stepner, D. E.↗
NASA NTRS2014

Conceptual Design Optimization of an Augmented Stability Aircraft Incorporating Dynamic Response Performance Constraints

This research focused on incorporating stability and control into a multidisciplinary de- sign optimization on a Boeing 737-class advanced concept called the D8.2b. A new method of evaluating the aircraft handling performance using quantitative evaluation of the sys- tem to disturbances, including perturbations, continuous turbulence, and discrete gusts, is presented. A multidisciplinary design optimization was performed using the D8.2b transport air- craft concept. The con guration was optimized for minimum fuel burn using a design range of 3,000 nautical miles. Optimization cases were run using xed tail volume coecients, static trim constraints, and static trim and dynamic response constraints. A Cessna 182T model was used to test the various dynamic analysis components, ensuring the analysis was behaving as expected. Results of the optimizations show that including stability and con- trol in the design process drastically alters the optimal design, indicating that stability and control should be included in conceptual design to avoid system level penalties later in the design process.

Welstead, Jason↗
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2025

Processing-dependent chemical ordering in Cu 3 Au characterized via non-destructive Bragg coherent diffraction imaging

Of current importance for alloy design is controlling chemical ordering through processing routes to optimize an alloy's mechanical properties for a desired application. However, characterization of chemical ordering remains an ongoing challenge, particularly when nondestructive characterization is needed. Here, in this study, Bragg coherent diffraction imaging is used to reconstruct morphology and lattice displacement in model Cu 3 Au nanocrystals that have undergone different heat treatments to produce variation in chemical ordering. The magnitudes and distributions of the scattering amplitudes (proportional to electron density) and lattice strains within these crystals are then analyzed to correlate them to the expected amount of chemical ordering present. Nanocrystals with increased amounts of ordering are found to generally have less extreme strains present and reduced strain distribution widths. In addition, statistical correlations are found between the spatial arrangement of scattering amplitude and lattice strains.

Warren, Nathaniel [Pennsylvania State Univ., Unive↗