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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
NASA NTRS1989

Characterization of failure processes in tungsten copper composites under fatigue loading conditions

A fractographic and metallographic investigation was performed on specimens of a tungsten fiber reinforced copper matrix composite (9 vol percent), which had experienced fatigue failures at elevated temperatures. Major failure modes and possible failure mechanisms, with an emphasis placed on characterizing fatigue damage accumulation, were determined. Metallography of specimens fatigued under isothermal cyclic loading suggested that fatigue damage initiates in the matrix. Cracks nucleated within the copper matrix at grain boundaries, and they propagated through cavity coalescence. The growing cracks subsequently interacted with the reinforcing tungsten fibers, producing a localized ductile fiber failure. Examinations of interrupted tests before final failure confirmed the suggested fatigue damage processes.

Kim, Yong-Suk↗
NASA NTRS2003

Analysis and Test Correlation of Proof of Concept Box for Blended Wing Body-Low Speed Vehicle

The Low Speed Vehicle (LSV) is a 14.2% scale remotely piloted vehicle of the revolutionary Blended Wing Body concept. The design of the LSV includes an all composite airframe. Due to internal manufacturing capability restrictions, room temperature layups were necessary. An extensive materials testing and manufacturing process development effort was underwent to establish a process that would achieve the high modulus/low weight properties required to meet the design requirements. The analysis process involved a loads development effort that incorporated aero loads to determine internal forces that could be applied to a traditional FEM of the vehicle and to conduct detailed component analyses. A new tool, Hypersizer, was added to the design process to address various composite failure modes and to optimize the skin panel thickness of the upper and lower skins for the vehicle. The analysis required an iterative approach as material properties were continually changing. As a part of the material characterization effort, test articles, including a proof of concept wing box and a full-scale wing, were fabricated. The proof of concept box was fabricated based on very preliminary material studies and tested in bending, torsion, and shear. The box was then tested to failure under shear. The proof of concept box was also analyzed using Nastran and Hypersizer. The results of both analyses were scaled to determine the predicted failure load. The test results were compared to both the Nastran and Hypersizer analytical predictions. The actual failure occurred at 899 lbs. The failure was predicted at 1167 lbs based on the Nastran analysis. The Hypersizer analysis predicted a lower failure load of 960 lbs. The Nastran analysis alone was not sufficient to predict the failure load because it does not identify local composite failure modes. This analysis has traditionally been done using closed form solutions. Although Hypersizer is typically used as an optimizer for the design process, the failure prediction was used to help gain acceptance and confidence in this new tool. The correlated models and process were to be used to analyze the full BWB-LSV airframe design. The analysis and correlation with test results of the proof of concept box is presented here, including the comparison of the Nastran and Hypersizer results.

Spellman, Regina L.↗
DOE OSTI2023

High-throughput and high-performance lithium-ion batteries via dry processing

A scalable powder-to-electrode dry processing strategy mainly based on powder dry mixing and rolling/calendering is rationally designed. The dry processed electrodes show lower tortuosity compared to that of conventional slurry-based electrodes. The dry-processed high-loading graphite anodes (6.6 mAh cm -2 ) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes (6.0 mAh cm -2 ) exhibit promising electrochemical performance in half-cells and full-cells. The full-cells with both electrodes from dry processing demonstrates superb rate performance to their counterpart with conventional slurry-based electrodes and delivers of capacity retentions of 74.1 % and 63.6 % over 400 and 800 cycles, respectively. Notably, the initial Coulombic efficiency of the dry processed graphite anodes is low ascribed to polytetrafluoroethylene binder. Finally, the results suggest that dry processing is promising for future lithium-ion battery manufacturing and also pinpoint the needs of modification for the polytetrafluoroethylene binder in the graphite anodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Cellulosic biofuel production using emulsified simultaneous saccharification and fermentation (eSSF) with conventional and thermotolerant yeasts

Abstract Background Future expansion of corn-derived ethanol raises concerns of sustainability and competition with the food industry. Therefore, cellulosic biofuels derived from agricultural waste and dedicated energy crops are necessary. To date, slow and incomplete saccharification as well as high enzyme costs have hindered the economic viability of cellulosic biofuels, and while approaches like simultaneous saccharification and fermentation (SSF) and the use of thermotolerant microorganisms can enhance production, further improvements are needed. Cellulosic emulsions have been shown to enhance saccharification by increasing enzyme contact with cellulose fibers. In this study, we use these emulsions to develop an emulsified SSF (eSSF) process for rapid and efficient cellulosic biofuel production and make a direct three-way comparison of ethanol production between S. cerevisiae , O. polymorpha , and K. marxianus in glucose and cellulosic media at different temperatures. Results In this work, we show that cellulosic emulsions hydrolyze rapidly at temperatures tolerable to yeast, reaching up to 40-fold higher conversion in the first hour compared to microcrystalline cellulose (MCC). To evaluate suitable conditions for the eSSF process, we explored the upper temperature limits for the thermotolerant yeasts Kluyveromyces marxianus and Ogataea polymorpha , as well as Saccharomyces cerevisiae , and observed robust fermentation at up to 46, 50, and 42 °C for each yeast, respectively. We show that the eSSF process reaches high ethanol titers in short processing times, and produces close to theoretical yields at temperatures as low as 30 °C. Finally, we demonstrate the transferability of the eSSF technology to other products by producing the advanced biofuel isobutanol in a light-controlled eSSF using optogenetic regulators, resulting in up to fourfold higher titers relative to MCC SSF. Conclusions The eSSF process addresses the main challenges of cellulosic biofuel production by increasing saccharification rate at temperatures tolerable to yeast. The rapid hydrolysis of these emulsions at low temperatures permits fermentation using non-thermotolerant yeasts, short processing times, low enzyme loads, and makes it possible to extend the process to chemicals other than ethanol, such as isobutanol. This transferability establishes the eSSF process as a platform for the sustainable production of biofuels and chemicals as a whole.

09 BIOMASS FUELS↗
NASA NTRSDate not supplied

High Temperature Material Property Data and Challenges to Thermal Process Model Predictions and In-Situ/Ex-Situ Measurements for Metallic Additive Manufacturing

Understanding and predicting performance properties of parts produced by metallic additive manufacturing has improved significantly over the past decade; however, difficult to measure material properties and process outcomes continue to be challenges. The qualification or certification of aerospace parts require extensive measures to quantify variable part properties in order to buy down the risk of component failure. The variability, inherent to the additive manufacturing, process adds unwanted uncertainty in the production of load critical structural components. Process modeling has proven valuable in providing predictions and context for understanding outcomes of the additive manufacturing process; however, these physically informed process models require material properties at temperatures that are difficult to measure and rarely available. Further, calibrating or validating such models is difficult because the process itself is challenging to measure. This talk will explore some of the challenges resulting from difficult to acquire input data by relating thermal process model predictions to in-situ and ex-situ optical microscopy measurements.

Process Model↗
DOE OSTI2020

Qualification of Processing Batches for Tank Closure Cesium Removal Through In-Tank Batch Contact Testing - 20470

The Tank Closure Cesium Removal (TCCR) process at the Savannah River Site (SRS) is currently processing waste from Tank 10H, generating decontaminated salt solution that is sent to Tank 11H. Transfers out of Tank 11H are then disposed of on site as a grout wasteform in the SRS Saltstone Processing Facility. This is a full-scale demonstration of the use of Crystalline Silicotitanate (CST) for the decontamination of aqueous nuclear waste supernate. CST primarily removes cesium from the high sodium alkaline feed, but also adsorbs strontium, actinides, and some other trace metals. The TCCR unit is an at-tank set of four ion exchange columns, with two typically being operated in series during waste processing. Tank 10H is serving a dual function as both the salt dissolution tank as well as the feed tank for the TCCR system. Prior to operation of TCCR, Tank 10H must undergo dissolution campaigns, dissolving the salt cake to form an aqueous salt solution (supernate). After each dissolution campaign, the supernate created must be qualified prior to processing through the TCCR system. Qualification includes detailed characterization of the supernate as well as in-tank batch contact tests to determine the equilibrium loading of Cs-137 on the CST ion exchange media (IONSIV{sup TM} R9120-Ba). In support of the in-tank batch contact testing, Savannah River National Laboratory (SRNL) developed a CST sample holder, also referred to as a 'tea-bag', to hold a measured amount (∼0.1 grams) of pretreated CST between stainless steel screens. The tea-bag fits within a standard stainless steel sample vial that has been modified to allow the flow of supernate to the CST. This sample holder is then immersed in the waste tank allowing free contact between the CST beads and the surrounding liquid, at an effectively infinite liquid-to-solid phase ratio. A pair of tea-bags are deployed in the tank for a period of 10 days for each batch, after which the CST is recovered, digested, and analyzed to determine the loading of cesium isotopes on the CST. This result then supports the TCCR column thermal loading limits for processing as part of the TCCR safety basis. This paper will discuss the design and testing of the CST sample holder, as well as results from the first few batches of waste qualified and subsequently processed through the TCCR system. In addition, results from analyses of Tank 11H samples, showing decontamination of the product will be included. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Evaluation of Autonomous Vehicle Sensing and Compute Load on a Chassis Dynamometer

The sensing and compute load auxiliary energy consumption in autonomous vehicles may be significant due to the large number of sensors and the high compute load from sensor processing and route planning. To understand this issue, this study investigates the top-down energy usage of an electric 2015 Kia Soul fully instrumented with state sensors and a state-specific computer for path planning and sensor processing. A chassis dynamometer was then used to evaluate the cases of (1) no sensors or computation, (2) only sensors operating, and (3) sensors plus compute load. The vehicle was operated autonomously on the dynamometer using a PolySync drive-kit with drive-by-wire longitudinal control. The DynoJet model 224xLC was used to adapt the eddy current dynamometer's road load parameters to comply with an Environmental Protection Agency drive schedule and to evaluate performance against the Argonne National Laboratory Digital Dynamometer Dataset. On the UDDS-HWFET combined driving cycle, the stock battery's range was reduced by 5.6% for sensors alone and 12.2% for sensors and compute load. These results show that the added sensing and compute auxiliary load from automated and autonomous systems is significant and that research efforts need to be spent investigating new energy efficient systems.

Brown, Nicholas E.↗
NASA NTRS1999

Development and Implementation of a Load-Controlled Friction Stir Welder

Lockheed Martin Michoud Space Systems, under contract to NASA/MSFC, has developed and implemented a friction stir weld tool that uses the magnitude of the spindle axial load to control the weld process. This tool was used during the process development phase and the assembly of a full-scale External Tank barrel section. Both position and load transducers are incorporated into the welder. The control algorithm allows either the position or load transducer to provide the command variable in a closed loop system. Initially, the position transducer was used to actively control the weld process and the axial load on the spindle was monitored and collected via data acquisition hardware. As part of the process development, the axial load was implemented as the command variable in the closed loop. The spindle position is monitored and used to set limits on spindle travel. A zero set point algorithm has also been developed for establishing the spindle position at the start of the weld process. In its current state, the welder operates in a dual mode in which the position control is used to plunge the pin tool to a specified depth at the initiation of the weld. The load control is then used to control the weld process. This control algorithm has been used to assemble a 27.5-ft diameter, 2195-T8 barrel using hardware designed for NASA's Space Transportation System External Tank.

Loftus, Z.↗
NASA NTRS1989

Time-correlated gust loads using Matched-Filter Theory and Random-Process Theory: A new way of looking at things

Two ways of performing time-correlated gust-load calculations are described and illustrated. The first is based on Matched Filter Theory; the second on Random Process Theory. Both approaches yield theoretically identical results and represent novel applications of the theories, are computationally fast, and may be applied to other dynamic-response problems. A theoretical development and example calculations using both Matched Filter Theory and Random Process Theory approaches are presented.

Pototzky, Anthony S.↗
NASA NTRS1987

A kinetic study of solar wind mass loading and cometary bow shocks

The kinetic processes associated with solar wind mass loading due to pickup of cometary ions, and the formation of cometary bow shocks were investigated numerically using a hybrid simulation code described by Leroy et al. (1981), in which solar wind protons and heavy cometary ions are treated kinetically, but the electrons are treated as a massless fluid. It was found that the solar wind decelaration and pickup of cometary ions take place through both the macroscopic electromagnetic fields embedded in the solar wind and the microscopic field associated with low-frequency electromagnetic waves that are generated by the unstable velocity distribution function of the cometary ions. The results of the main simulation runs at various cone angles are described and compared with the recent observations of comets Giacobini-Zinner and Halley.

Omidi, N.↗
NASA NTRS1974

Fractional watt Vuillemier cryogenic refrigerator program engineering notebook. Volume 1: Thermal analysis

The cryogenic refrigerator thermal design calculations establish design approach and basic sizing of the machine's elements. After the basic design is defined, effort concentrates on matching the thermodynamic design with that of the heat transfer devices (heat exchangers and regenerators). Typically, the heat transfer device configurations and volumes are adjusted to improve their heat transfer and pressure drop characteristics. These adjustments imply that changes be made to the active displaced volumes, compensating for the influence of the heat transfer devices on the thermodynamic processes of the working fluid. Then, once the active volumes are changed, the heat transfer devices require adjustment to account for the variations in flows, pressure levels, and heat loads. This iterative process is continued until the thermodynamic cycle parameters match the design of the heat transfer devices. By examing several matched designs, a near-optimum refrigerator is selected.

Miller, W. S.↗
DOE OSTI2021

OPFLearnData: Dataset for Learning AC Optimal Power Flow

The datasets are resulting from OPFLearn.jl, a Julia package for creating AC OPF datasets. The package was developed to provide researchers with a standardized way to efficiently create AC OPF datasets that are representative of more of the AC OPF feasible load space compared to typical dataset creation methods. The OPFLearn dataset creation method uses a relaxed AC OPF formulation to reduce the volume of the unclassified input space throughout the dataset creation process. The dataset contains load profiles and their respective optimal primal and dual solutions. Load samples are processed using AC OPF formulations from PowerModels.jl. More information on the dataset creation method can be found in our publication, "OPF-Learn: An Open-Source Framework for Creating Representative AC Optimal Power Flow Datasets" and in the package website: https://github.com/NREL/OPFLearn.jl.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Scalable Deep Learning-Based Microarchitecture Simulation on GPUs

Cycle-accurate microarchitecture simulators are essential tools for designers to architect, estimate, optimize, and manufacture new processors that meet specific design expectations. However, conventional simulators based on discrete-event methods often require an exceedingly long time-to-solution for the simulation of applications and architectures at full complexity and scale. Given the excitement around wielding the machine learning (ML) hammer to tackle various architecture problems, there have been attempts to employ ML to perform architecture simulations, such as Ithemal and SimNet. However, the direct application of existing ML approaches to architecture simulation may be even slower due to overwhelming memory traffic and stringent sequential computation logic. This work proposes the first graphics processing unit (GPU)-based microarchitecture simulator that fully unleashes the potential of GPUs to accelerate state-of-the-art ML-based simulators. First, considering the application traces are loaded from central processing unit (CPU) to GPU for simulation, we introduce various designs to reduce the data movement cost between CPUs and GPUs. Second, we propose a parallel simulation paradigm that partitions the application trace into sub-traces to simulate them in parallel with rigorous error analysis and effective error correction mechanisms. Combined, this scalable GPU-based simulator outperforms by orders of magnitude the traditional CPU-based simulators and the state-of-the-art ML-based simulators, i.e., SimNet and Ithemal.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Low and High LET Degradation Studies of Metal-Loaded Organic Phase Ligands in the ALSEP Process

Organic solutions comprising the Actinide Lanthanide Separation Process (ALSEP) solvent consisting of 0.5 M 2-ethylhexyl phosphonic acid mono-2-ethylhexyl ester (HEH[EHP]) and 0.05 M N,N,N’,N’-tetra(2-ethylhexyl)diglycolamide (T2EHDGA) in n-dodecane were subjected to low LET and high LET irradiation before and after equilibration with an aqueous phase of 3 M HNO 3 . Degradation dose constants revealed greater ligand degradation due to gamma irradiation than alpha irradiation for both ligands. Furthermore, equilibration with nitric acid did not have a significant impact on ligand degradation for either irradiation source. Identified degradation products were similar for both gamma and alpha irradiation and occurred mostly through the rupture of the N–C carbonyl and C–O ether bonds for T2EHDGA and the C–Oether bond in HEH[EHP]. Acid contact appears to alter the degradation pathway by favoring the formation of higher molecular weight recombination products. Furthermore, mixed T2EHDGA-HEH[EHP]-NO 3 complexes were formed with Nd(III) after extraction from 3 M HNO 3 , and low LET gamma irradiation of the Nd(III) loaded organic solution produced similar degradation products as the organic solution absent of Nd(III). Interestingly, and likely due to the greater radiolytic susceptibility of T2EHDGA than HEH[EHP], a HEH[EHP]-Nd(III) complex appears to form as the T2EHDGA degrades with increasing absorbed dose.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1985

Planetary reorientation by surface loads

Non-hydrostatic concentrations of mass at the surface of the planet have been suggested as mechanisms of permanent reorientation for all of the terrestrial planets and for the Moon. In order for such a load to control planetary orientation, three conditions must be satisfied. The surface load must be non-hydrostatically supported; the surface load must be large compared to internal departures from a hydrostatic mass distribution; and the load must be large compared to hydrostatic departures of the planetary figure from a sphere. The third condition comes from the consideration that if the load is non-hydrostatically supported, then the same processes which support the load will also the hydrostatic figure.

Willemann, R. J.↗
DOE OSTI2020

High solids loading biorefinery for the production of cellulosic sugars from bioenergy sorghum

A novel process applying high solids loading in chemical-free pretreatment and enzymatic hydrolysis was developed to produce sugars from bioenergy sorghum. Hydrothermal pretreatment with 50% solids loading was performed in a pilot scale continuous reactor followed by disc refining. Sugars were extracted from the enzymatic hydrolysis at 10% to 50% solids content using fed-batch operations. Here, three surfactants (Tween 80, PEG 4000, and PEG 6000) were evaluated to increase sugar yields. Hydrolysis using 2% PEG 4000 had the highest sugar yields. Glucose concentrations of 105, 130, and 147 g/L were obtained from the reaction at 30%, 40%, and 50% solids content, respectively. The maximum sugar concentration of the hydrolysate, including glucose and xylose, obtained was 232 g/L. Additionally, the glucose recovery (73.14%) was increased compared to that of the batch reaction (52.74%) by using two- stage enzymatic hydrolysis combined with fed-batch operation at 50% w/v solids content.

09 BIOMASS FUELS↗
DOE OSTI2020

Data from High Solids Loading Biorefinery for the Production of Cellulosic Sugars from Bioenergy Sorghum

A novel process applying high solids loading in chemical-free pretreatment and enzymatic hydrolysis was developed to produce sugars from bioenergy sorghum. Hydrothermal pretreatment with 50% solids loading was performed in a pilot scale continuous reactor followed by disc refining. Sugars were extracted from the enzymatic hydrolysis at 10% to 50% solids content using fed-batch operations. Three surfactants (Tween 80, PEG 4000, and PEG 6000) were evaluated to increase sugar yields. Hydrolysis using 2% PEG 4000 had the highest sugar yields. Glucose concentrations of 105, 130, and 147 g/L were obtained from the reaction at 30%, 40%, and 50% solids content, respectively. The maximum sugar concentration of the hydrolysate, including glucose and xylose, obtained was 232 g/L. Additionally, the glucose recovery (73.14%) was increased compared to that of the batch reaction (52.74%) by using two-stage enzymatic hydrolysis combined with fed-batch operation at 50% w/v solids content.

Conversion↗
NASA NTRS2015

Plasma Waves Associated with Mass-Loaded Comets

Plasma waves and instabilities are integrally involved with the plasma "pickup" process and the mass loading of the solar wind (thus the formation of ion tails and the magnetic tails). Anisotropic plasmas generated by solar wind-comet interactions (the bow shock, magnetic field pileup) cause the generation of plasma waves which in turn "smooth out" these discontinuities. The plasma waves evolve and form plasma turbulence. Comets are perhaps the best "laboratories" to study waves and turbulence because over time (and distance) one can identify the waves and their evolution. We will argue that comets in some ways are better laboratories than magnetospheres, interplanetary space and fusion devices to study nonlinear waves and their evolution.

instabilities↗