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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Mesocrystal growth through oriented sliding and attachment of nanoplates

Oriented attachment is a critical, yet poorly understood, crystal growth pathway based on the self-assembly of nanocrystals. During oriented attachment, solvent-separated particles align and coalesce through forces that enable precise rotation and translation. While prior studies emphasized intragap forces driving crystallographic alignment, the forces enabling uniform stacking and superlattice formation remain unclear. Here, we demonstrate how macroscopic gibbsite mesocrystals emerge from nanoplates guided into staggered positions by directional sliding. Electron microscopy and X-ray scattering reveal the monoclinic superlattice structure, based on nanoplate stacking with a uniform ≈50° stagger along the gibbsite [010] direction. In situ liquid-cell TEM captures preferential sliding along the gibbsite [010] direction, decelerating with increasing particle overlap. Molecular dynamics simulations reveal that this staggered arrangement corresponds to a global free-energy minimum, rather than full alignment. The simulations also confirm that sliding along the [010] direction is energetically favored and provide insight into the role of interfacial water in achieving long-range ordered assemblies. These insights highlight the energy landscape’s role in oriented attachment, with implications for material synthesis and hierarchical structures in nature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

srlife: A Fast Tool for High Temperature Receiver Design and Analysis

This report describes a tool for estimating the structural service life of tubular, panel solar receivers operating at high temperatures. A complete version of the tool is available as open source software at https://github.com/Argonne-National-Laboratory/srlife and can be installed through the PyPi (https://pypi.org) package manager. Given the basic receiver geometry and the thermal loads on the receiver, the tool provides 1D, 2D, or 3D thermal and structural (single tube and simplified system) analysis and creep-fatigue service life prediction for six metallic alloys – 316H, 800H, Alloy 617, Alloy 740H, and Alloy 230. With the exception of Alloy 230 where the material data is preliminary, the software included a detailed set of models for the materials, well-supported by high temperature experimental test data. The tool is designed for easy integration with a software stack, including solar field and thermohydraulic simulations, for optimizing receiver designs to meet service life and economic targets. The report describes several heuristics that can be applied in srlife to reduce the analysis time by several orders of magnitude but with fairly accurate life estimation when compared with full analysis. The report provides several examples demonstrating the utility of srlife in receiver design. Finally, the report discusses high temperature tests on Alloy 282, collected as part of this project, used to develop and support the material model for that alloy.

47 OTHER INSTRUMENTATION↗
NASA NTRS2004

Frequency Spectrum for New Aviation Data Links: Initial Study Results

We describe results from an initial study to assess the suitability of various spectral bands for supporting the deployment of new aviation data links (ADL). The study focused on systems and spectral bands that can deliver VHF data link (VDL)-or-higher data rates in a two-way communication setting, including air-ground, ground-air, and air-air modes of operation. In the first part of our paper, we briefly discuss the current situation regarding communications, navigation, and surveillance (CNS) links and existing spectrum, and the well-known need for new aviation data links. We next provide an overview of related systems, and discuss key factors involved in the use of spectrum in various bands for any future integrated CNS data link, addressing primarily the lower few layers of the communications protocol stack. Desired attributes of a new ADL system are discussed, and the beneficial aspects of a particular transmission technique spread spectrum are summarized. We also provide a short list of several example potential spectral regions, and note that while none of the existing systems will likely meet the full range of desired features of a new ADL, several systems and spectral regions offer promise in terms of one or more characteristics. A detailed discussion and evaluation of these spectral regions is proposed as future work. We include a few brief examples to illustrate initial technical results regarding spread spectrum overlay, also a subject for future work.

Matolak, David W.↗
NASA NTRS2016

Ultrasonic Nondestructive Evaluation of Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) During Large-Scale Load Testing and Rod Push-Out Testing

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept developed by the Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration. The HWB has long been a focus of NASA's environmentally responsible aviation (ERA) project, following a building block approach to structures development, culminating with the testing of a nearly full-scale multi-bay box (MBB), representing a segment of the pressurized, non-circular fuselage portion of the HWB. PRSEUS is an integral structural concept wherein skins, frames, stringers and tear straps made of variable number of layers of dry warp-knit carbon-fiber stacks are stitched together, then resin-infused and cured in an out-of-autoclave process. The PRSEUS concept has the potential for reducing the weight and cost and increasing the structural efficiency of transport aircraft structures. A key feature of PRSEUS is the damage-arresting nature of the stitches, which enables the use of fail-safe design principles. During the load testing of the MBB, ultrasonic nondestructive evaluation (NDE) was used to monitor several sites of intentional barely-visible impact damage (BVID) as well as to survey the areas surrounding the failure cracks after final loading to catastrophic failure. The damage-arresting ability of PRSEUS was confirmed by the results of NDE. In parallel with the large-scale structural testing of the MBB, mechanical tests were conducted of the PRSEUS rod-to-overwrap bonds, as measured by pushing the rod axially from a short length of stringer.

Johnston, Patrick H.↗
NASA NTRS1981

Develop and test fuel cell powered on-site integrated total energy system. Phase 3: Full-scale power plant development

An integrated 5 kW power system based upon methanol fuel and a phosphoric acid fuel cell operating at about 473 K is described. Description includes test results of advanced fuel cell catalysts, a semiautomatic acid replenishment system and a completed 5 kW methanol/system reformer. The results of a preliminary system test on a reformer/stack/inverter combination are reported. An initial design for a 25 kW stack is presented. Experimental plans are outlined for data acquisition necessary for design of a 50 kW methanol/steam reformer. Activities related to complete mathematical modelling of the integrated power system, including wasteheat utilization, are described.

Kaufman, A.↗
NASA NTRS2009

Astronaut Thermal Exposure: Re-Entry After Low Earth Orbit Rescue Mission

The STS-125 mission, launched May 11, 2009, is the final servicing mission to the Hubble Space Telescope. The repair mission's EVA tasks are described, including: installing a new wide field camera; installing the Cosmic Origins Spectrograph; repairing the Space Telescope Imaging Spectrograph; installing a new outer blanket layer; adding a Soft Capture and Rendezvous System for eventual controlled deorbit in about 2014; replacing the 'A' side Science Instrument Command and Data Handling module; repairing the Advanced Camera for surveys; and, replacing the rate sensor unit gyroscopes, fine guidance sensors and 3 batteries. Additionally, the Shuttle crew cabin thermal environment is described. A CFD model of per person CO2 demonstrates a discrepancy between crew breathing volume and general mid-deck levels of CO2. A follow-on CFD analysis of the mid-deck temperature distribution is provided. Procedural and engineering mitigation plans are presented to counteract thermal exposure upon reentry to the Earth atmosphere. Some of the procedures include: full cold soak the night prior to deorbit; modifying deck stowage to reduce interference with air flow; and early securing of avionics post-landing to reduce cabin thermal load prior to hatch opening. Engineering mitigation activities include modifying the location of the aft starboard ICUs, eliminating the X3 stack and eliminating ICU exhaust air directed onto astronauts; improved engineering data of ICU performance; and, verifying the adequacy of mid-deck temperature control using CFD models in addition to lumped parameter models. Post-mitigation CFD models of mid-deck temperature profiles and distribution are provided.

Gillis, David B.↗
DOE OSTI2026

A Dendrite-Resistant Sodium/Porous-Carbon Anode for Solid-State Batteries – Strategies and Challenges for Low-Pressure Operation

Sodium solid-state batteries (Na-SSB) have gained interest recently due to the abundance of Na over Li, but they still tend to fail due to dendrites under practical current densities and cycling capacities. To overcome this, Na-SSBs are frequently tested with impractically high applied pressure. In this work, a porous carbon interfacial layer is utilized in conjunction with Na-ß”-Al2O3 solid electrolytes to enable Na-cycling at milder cell pressures. This sodium/porous carbon layer enables improved solid-state Na cycling in symmetric cells, up to a current density of 10 mA cm-2 at 25 °C. Cycling up to 1 mAh cm-2 is challenging with low pressure, but 1 mAh cm-2 capacity can be reliably cycled at 1 mA cm-2 at an elevated temperature of 60 °C in symmetric cells. Finally, the evolution of the interface and sodium/carbon anode is evaluated with cryogenic ion-milling and cross-sectional imaging revealing that, depending on testing temperature, pressure, current density, and capacity, void formation, Na-extraction from porous carbon, delamination of the porous carbon matrix, or a combination of these occurs at the interface between Na-metal and BASE. Despite this, excellent dendrite resistance is achieved, and a full-cell design utilizing a Na-transition metal oxide cathode is still able to achieve an areal capacity of ~ 2.7 mAh cm-2 at 0.125 mA cm-2. This work demonstrates an alternative pathway toward a Na-metal anode for Na-SSBs without the requirement of excessive stack pressure.

low-cost↗
DOE OSTI2021

Wyoming CarbonSAFE: Advancing Commercialization of Low-Carbon Energy Technologies in Fossil-Rich Wyoming

Wyoming’s Powder River Basin (PRB) is the most prolific coal producer and exporter in the United States and the State of Wyoming’s largest oil-producing basin. In addition to being a leading energy producer, the PRB is the site of research programs whose aim is to develop and integrate low-carbon technologies into existing fossil fuel energy industries. Much of the PRB’s low-carbon research is focused around Dry Fork Station (DFS), which is the newest coal-fired power station in the western US. Currently, DFS hosts five carbon capture projects, including pilot-scale capture projects that utilize different capture technologies and a full front-end engineering and design (FEED) study, a commercial CO 2 pipeline for nearby CO 2 -enhanced oil recovery industry, and is also co-located with the Wyoming Integrated Test Center, which is a host facility for unconventional carbon utilization research (i.e. flue gas carbon-to-products innovations). DFS is also the host site for the Wyoming CarbonSAFE project. Wyoming CarbonSAFE, funded by the Department of Energy/National Energy Technology Laboratory, is a multi-phased program (currently in Phase II) whose core objective is developing and validating storage sites within a complex capable of storing 50 million metric tonnes of CO 2 over a 30 year project period using carbon capture, utilization and storage (CCUS). This paper will provide an overview of the project to-date, showing that CarbonSAFE goals are achievable with respect to geologic, environmental, regulatory, CO 2 source and economic conditions, and why the State of Wyoming offers one of the more favorable environments to advance the commercialization studies. In 2019, the project team designed and completed a ~10,000 foot stratigraphic test well just south of DFS. From this well, the team collected over 600 feet of core, fluid samples from target injection zones, and a full petrophysical log suite. In addition, legacy 2D seismic lines were acquired and a 3D seismic survey was acquired in the fall of 2020. The objective of these field activities has been to identify and characterize target storage reservoirs and associated caprock. This complex has several reservoirs that could meet commercial injection goals, and over 4000 feet of associated caprock. Simulations of site performance suggest that stacked injection provides the most effective storage strategy, and would necessitate several sites within the greater complex to meet final project injection goals. Other work within this project includes the development of a business-case around proximal fields with CO 2 -enhanced oil recovery potential and existing tax credits, assessment of regulatory conditions, including pore space ownership and Class VI injection well permitting requirements, implementation of a robust public outreach Electronic copy available at: https://ssrn.com/abstract=3821220 GHGT-15 McLaughlin 2 program, and surface site characterization activities that have focused on environmental factors. In the PRB and at DFS, the State of Wyoming and other entities have made carbon management a priority of its future energy industry by providing a regulatory and business framework that is favorable to advancing these technologies. These endeavors will become more realistic with the successful implementation of Wyoming CarbonSAFE, and its ability to secure and validate commercial-scale CCUS at the center of Wyoming’s premier low-carbon research efforts.

McLaughlin, Fred↗
NASA NTRS1991

Evaluation of some scale effects in the response and failure of composite beams

The feasibility of using scale model testing for predicting full-scale behavior of composite beams loaded in tension and flexure was investigated. Classical laws of similitude were applied to fabricate and test replica model beams to identify scaling effects in the load response, strength, and mode of failure. Experiments were conducted using graphite-epoxy composite beams having different laminate stacking sequences and a range of scaled sizes. Results indicated that the elastic response of scaled composite beams was independent of specimen size. However, a significant scale effect in strength was observed. In addition, a transition in failure mode was observed among scaled beams of certain laminate stacking sequences. Weibull statistical and fracture mechanics based models were applied to predict the strength scale effect since standard failure criteria cannot account for the influence of absolute specimen size in failure.

Jackson, Karen E.↗
DOE OSTI2021

Stage 2 Full-Scale Rotary Magnetic Gear for a Marine Hydrokinetic Generator

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. Experimental Testing Data for a 6.66:1 gear ratio dual-stack magnetic gear with a measured peak torque of 1391 N-m

16 TIDAL AND WAVE POWER↗
NASA NTRS1981

Cell module and fuel conditioner development

The test results of and post test analysis of Stack 559 are reported. The design features and construction status of Stacks 560, 561, 562 and 563 are described. The measurements of cell materials compressibility are rationalized and summarized and an explanation of their uses is given. Preliminary results of a manifold material/coating survey are given. The results of shift converter catalyst performance tests and reforming catalyst aging tests are reported. State points for full load and part load operation of the fuel conditioning subsystem tabulated. Work on the data base for the fuel conditioner ancillary subsystems is summarized.

Hoover, D. Q., Jr.↗
NASA NTRS1986

Large area space qualified thermoelectrically (TE) cooled HgCdTe MW photovoltaic detectors for the Halogen Occultation Experiment (HALOE)

Large-area, HgCdTe MW photovoltaic detectors have been developed for the NASA-HALOE instrument scheduled for operation on the Upper Atmospheric Research Satellite. The photodiodes will be TE-cooled and were designed to operate in the 5.1-5.4 micron band at 185 K to measure nitric oxide concentrations in the atmosphere. The active area required 15 micron thick devices and a full backside common contact. Reflections from the backside contact doubled the effective thickness of the detectors. Optical interference from reflections was eliminated with a dual layer front surface A/R coating. Bakeout reliability was optimized by having Au metallization for both n and p interconnects. Detailed performance data and a model for the optical stack are presented.

Norton, P. W.↗
DOE OSTI2024

A Bayesian Learning Approach to Wireless Outdoor Heatmap Construction using Deep Gaussian Process

We present a novel Bayesian learning approach to outdoor radio heatmap construction utilizing deep Gaussian process (GP). The proposed approach employs a two-layer hierarchy which consists of two cascaded Gaussian processes that are capable of modeling more complex input-output relations than standard single-layer Gaussian processes. Since deriving the exact model likelihood is challenging, a lower bound is optimized instead so that gradient descent-based methods can be performed to find out the optimal model parameters. Typically, inducing points are used in GPs to facilitate low-rank approximation of covariance (kernel) matrices for computation speedup. However, the inaccuracy induced by inducing points can accumulate when stacking multiple layers of GP which may hinder the performance of deep GP. Moreover, since inducing points need to be learned, having them at all layers of deep GP also incurs computational burden. To overcome the above challenges, in contrast to the canonical deep GP model, we use a modified architecture where a full standard GP resides in the first layer and inducing points are only introduced for the second layer. This modified architecture strikes a balance between model accuracy and training complexity. In the proposed model, the noise parameter of the first GP layer is also eliminated to improve the training efficiency as the noise parameter at the output of the second layer suffices to model the uncertainty in the output. The proposed approach is evaluated on real-world datasets, in the form of location-Received Signal Strength (RSS) pairs, collected from the Platform for Open Wireless Data-driven Experimental Research (POWDER) located at the campus of the University of Utah. Experiment results show that the proposed approach can achieve smaller prediction errors on various training and testing data configurations than DNN-based and GP-based methods.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗
NASA NTRS1981

Develop and test fuel cell powered on-site integrated total energy systems. Phase 3: Full-scale power plant development

A schematic and physical layout is given for the 5kW integrated system and the development status of individual components is described. The results of using a one dimensional mathematical model of the 5kW reformer are presented. Plans for a single-tube reformer test unit for the acquisition of temperature profile data are described. Tentative specifications for a 50kW dc-to-ac inverter are listed. Performance data are given on two 3-cell stacks incorporating semiautomatic acid replenishment systems and improved electrocatalysts. A qualification test on methanol/steam reforming catalyst T2107RS is reported, including a portion in which the catalyst was deliberately poisoned with 800 ppm ethanol in the feed.

Source record↗
NASA NTRS2015

Advanced Mirror Technology Development (AMTD) Project: 3.0 Year Status

Advanced Mirror Technology Development (AMTD) is a funded NASA Strategic Astrophysics Technology project. Begun in 2011, we are in Phase 2 of a multi-year effort. Our objective is to mature towards TRL6 critical technologies needed to produce 4-m or larger flight-qualified UVOIR mirrors by 2018 so that a viable astronomy mission can be considered by the 2020 Decadal Review. The developed technology must enable missions capable of both general astrophysics and ultra-high contrast observations of exoplanets. Just as JWST's architecture was driven by launch vehicle, a future UVOIR mission's architecture (monolithic, segmented or interferometric) will depend on capacities of future launch vehicles (and budget). Since we cannot predict the future, we must prepare for all potential futures. Therefore, we are pursuing multiple technology paths. AMTD uses a science-driven systems engineering approach. We mature technologies required to enable the highest priority science AND result in a high-performance low-cost low-risk system. One of our key accomplishments is that we have derived engineering specifications for advanced normal-incidence monolithic and segmented mirror systems needed to enable both general astrophysics and ultra-high contrast observations of exoplanets missions as a function of potential launch vehicle and its inherent mass and volume constraints. Another key accomplishment is that we have matured our technology by building and testing hardware. To demonstrate stacked core technology, we built a 400 mm thick mirror. Currently, to demonstrate lateral scalability, we are manufacturing a 1.5 meter mirror. To assist in architecture trade studies, the Engineering team develops Structural, Thermal and Optical Performance (STOP) models of candidate mirror assembly systems including substrates, structures, and mechanisms. These models are validated by test of full- and subscale components in relevant thermo-vacuum environments. Specific analyses include: maximum mirror substrate size, first fundamental mode frequency (i.e., stiffness) and mass required to fabricate without quilting, survive launch, and achieve stable pointing and maximum thermal time constant.

Stahl, H. Philip↗
NASA NTRS1992

Scale effects in the response and failure of fiber reinforced composite laminates loaded in tension and in flexure

The feasibility of using scale model testing for predicting the full-scale behavior of flat composite coupons loaded in tension and beam-columns loaded in flexure is examined. Classical laws of similitude are applied to fabricate and test replica model specimens to identify scaling effects in the load response, strength, and mode of failure. Experiments were performed on graphite-epoxy composite specimens having different laminate stacking sequences and a range of scaled sizes. From the experiments it was deduced that the elastic response of scaled composite specimens was independent of size. However, a significant scale effect in strength was observed. In addition, a transition in failure mode was observed among scaled specimens of certain laminate stacking sequences. A Weibull statistical model and a fracture mechanics based model were applied to predict the strength scale effect since standard failure criteria cannot account for the influence of absolute specimen size on strength.

Jackson, Karen E.↗