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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Damage Tolerance Assessment of Laser Clad Repairs of Coarse Grain Ti-6Al-4V

Background: Laser cladding offers a promising approach to repairing aviation components, with the ability to restore the geometric shape and the static and fatigue strength. Objective: The damage tolerance of a coarse grain Ti-6Al-4 V material is assessed via three sets of samples: (i) baseline, (ii) laser clad repaired, and (iii) laser cladding followed by heat treatment. Method: The specimens were subjected to fatigue loading using a marker band technique, in which cracks initiated from pre-defined laser slots and the small crack growth rates were measured by quantitative fractography. Additional characterization was performed on these samples, including hardness measurements, microstructure analysis, and multimodal residual stress analyses. Results: The region of the specimen undergoing laser cladding exhibited higher hardness values and a compressive residual stress, based on the slitting method. The samples subjected to heat treatment after cladding displayed negligible differences in grain size and minimal residual stress relaxation. Conclusions: The results demonstrated significant variability, with data demonstrating that cracks in the laser clad region (exhibiting the largest compressive residual stress) grew faster than cracks in the substrate region of the sample or in the baseline cases. Finally, these counterintuitive results are rationalized with additional analyses from synchrotron-based energy dispersive X-ray diffraction and high energy X-ray diffraction, demonstrating significant spatial variability in the residual elastic strains in the millimeter-sized prior β grains within the material.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Toward control co-design of utility-scale wind turbines: Collective vs. individual blade pitch control

A large-eddy simulation framework has been coupled with controller modules to systematically investigate the impacts of collective (CPC) and individual (IPC) pitch control strategies on utility-scale wind turbine energy production and fatigue loads. Wind turbine components were parameterized using an actuator surface model to simulate the rotor blades and the turbine nacelle. The baseline CPC and IPC algorithms, consisting of single-input single-output proportional–integral controllers and two integral controllers, respectively, were incorporated into the numerical framework. A series of simulations were carried out to investigate the relative performance of the two controllers under various turbulent inflow conditions, spanning hub-height velocities of 7 to 14 m/s. The numerical simulation results of this study showed that, in comparison to the CPC, the IPC controller could successfully reduce the damage equivalent loads of utility-scale turbines at regions 2 and 3 of turbine operation by about 3% and 40%, respectively, without any penalty on the power production of the turbine. It was also shown that, despite its minor impact on the turbulence kinetic energy of the wake, the IPC controller did not influence the recovery of the turbine wake.

17 WIND ENERGY↗
DOE OSTI2023

Large-eddy simulations of turbulent flows in arrays of helical- and straight-bladed vertical-axis wind turbines

Effects of helical-shaped blades on the flow characteristics and power production of finite-length wind farms composed of vertical-axis wind turbines (VAWTs) are studied numerically using large-eddy simulation (LES). Two helical-bladed VAWTs (with opposite blade twist angles) are studied against one straight-bladed VAWT in different array configurations with coarse, intermediate, and tight spacings. Statistical analysis of the LES data shows that the helical-bladed VAWTs can improve the mean power production in the fully developed region of the array by about 4.94%–7.33% compared with the corresponding straight-bladed VAWT cases. The helical-bladed VAWTs also cover the azimuth angle more smoothly during the rotation, resulting in about 47.6%–60.1% reduction in the temporal fluctuation of the VAWT power output. Using the helical-bladed VAWTs also reduces the fatigue load on the structure by significantly reducing the spanwise bending moment (relative to the bottom base), which may improve the longevity of the VAWT system to reduce the long-term maintenance cost.

17 WIND ENERGY↗
DOE OSTI2020

Enhancement of Unsteady and 3D Aerodynamics Models using Machine Learning

Unsteady aerodynamics will be an important part of the floating wind turbines of the future operating under high shear across the rotor disk coupled with platform motion and atmospheric turbulence. We develop an unsteady aerodynamics and dynamic stall model using a long short-term memory variant of recurrent neural networks. The neural network model is trained using the oscillating airfoil data set from Ohio State University. The predictions from our machine learning (ML)-based model show good agreement with the experimental data and other state-of-the-art dynamic stall models for a wide range of airfoils, Reynolds numbers and reduced frequencies. In some cases the predictions are better than the Beddoes-Leishman model implementation in OpenFAST, when using the default coefficients. The ML-based model is also able to capture the key physics associated with dynamic stall, such as the precedence of moment stall before lift stall and cycle-to-cycle variations in the aerodynamic response. The new unsteady aerodynamics model is expected to improve prediction of fatigue loads for yaw-based wake-steering control scenarios in actuator-line and actuator-disc simulations of wind farms. Our methodology for training the ML-model provides a pathway for improving design level tools using high-fidelity computational fluid dynamics (CFD) simulations in the future.

17 WIND ENERGY↗
DOE OSTI2024

Development and Verification of an Improved Wake-Added Turbulence Model in FAST.Farm

We introduce a generalized wake-added turbulence (WAT) model in the multiphysics, multiturbine simulation tool FAST.Farm. The WAT model introduces additional small-scale turbulence that represents the breakdown of vortical structures and shear layers in the wake. The article describes the development, implementation, calibration, and verification of the model. The novelties of the model include support for wake asymmetry, buildup of WAT across the wind farm, and secondary effects of wake-induced turbulence (e.g., wake meandering) driven by smaller-scale turbulence structures that arise from wake breakdown. Large-eddy simulations were run to support the calibration of the WAT parameters and verification of the model. Previous studies hypothesized that the lack of WAT modeling was the source of underprediction of fatigue loads, in particular for cases at low turbulence intensities and/or stable atmospheric boundary layers. This study confirms that the newly implemented WAT model enhances the loads predictions in these cases.

17 WIND ENERGY↗
DOE OSTI2026

Closed-Loop Wind Turbine Controllers for Active Wake Mixing Strategies

Wind turbine active wake mixing (AWM) is an exciting new field of research where dynamic actuation, usually on the blade pitch angles, is used to increase wind farm-wide power production. From a controls perspective, the current state-of-the-art AWM strategies are very simple: a dynamic, usually periodic, reference signal is prescribed to actuators in an open-loop (OL) fashion. The actuation is then presumed to have a certain desired effect on the system, i.e., the wind turbine and the flow it affects. However, this system is highly nonlinear and experiences disturbances in the form of wind variations that are not known a priori. As a result, the OL approach might not yield optimal results. In this article, a novel approach is presented, which closes the loop on AWM controllers. A feedback loop is implemented, which uses measurements of the individual blade bending moments that are widely available on modern wind turbines to determine the individual blade pitch angles. A proof of concept of this implementation is presented in this article, and a thorough comparison with the OL method is executed using high-fidelity flow simulations. These simulations show that the novel closed-loop controller does not substantially increase wake mixing but achieves similar performance as the OL controller while reducing fatigue loads on the controlled turbine.

17 WIND ENERGY↗
DOE OSTI2023

Grid Forming Fast Frequency Response for PMSG-Based Wind Turbines

Electric power systems are undergoing a rapid transition from fuel-based generation using synchronous generators to renewable generation interfaced by power electronics. In this context, a key challenge is using renewable generation with limited controllability to contribute to power system stability. In this work, we investigate grid-forming control of permanent magnet synchronous generator (PMSG) wind turbines. The proposed control and curtailment strategy supports the entire spectrum of standard functions of grid-following (e.g. maximum power point tracking (MPPT) and grid-forming control (e.g., primary frequency control) without explicit mode switching. A detailed case study is used to compare the performance of the proposed control at operating points corresponding to MPPT and frequency control with standard grid-forming and grid-following controls. Further, the results demonstrate that (i) the proposed energy balancing grid forming control is self-synchronizing in MPPT mode, (ii) the (limited) energy storage and controllability of wind turbines can be adequately utilized to provide grid support, and (ii) the proposed control exhibits good performance under variable wind speeds and does not result in a significant increase of wind turbine fatigue loads.

17 WIND ENERGY↗
DOE OSTI2021

Structural response of 3D-printed rubber lattice structures under compressive fatigue

In this work, a new direct UV curing, polyurethane-like, highly stretchable rubber, Elastic ToughRubber 90™ (ETR 90), is demonstrated for 3D printing via photocuring with Texas Instruments DLP® optical systems. An array of test specimens, comprising a sandwich structure with a body-centered cubic lattice core, are 3D printed from ETR 90. The compressive behavior of these specimens is characterized up to 10 k and up to 100 k fatigue-loading cycles. The internal, visually obstructed, structures under loads are visualized using in situ X-ray tomography. All lattice structures remain intact and full recovery is observed, indicating the cyclic durability of the 3D-printed rubber.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A physics-informed data-driven low order model for the wind velocity deficit at the wake of isolated buildings

Detailed simulations of the Atmospheric boundary layer (ABL) provides information on wind velocity, direction and turbulence for optimizing the design of wind turbines and wind farms and their operations. Distributed wind turbines have been considered for use in urban or suburban areas for covering energy needs using a sustainable energy solution. Simulations of high Reynolds number turbulent ABL flows past obstacles can be used for the prediction of the velocity deficit and turbulence characteristics in the leeward side of building-like obstacles, allowing for the estimation of power losses and fatigue loads in wind turbines. However, fully three-dimensional simulations of high Reynolds number ABL flows using Large Eddy Simulation (LES) or Reynolds Average Navier-Stokes Simulations (RANS) continue to require large computational/ execution times. As a result, these 3D simulations may not be ideal tools for the rapid assessment of wind energy potential. In the present study, 3D numerical results from wall resolved RANS simulations were used for the development of a low order model that allows the rapid assessment of wind velocity and turbulence in the leeward side of an isolated building.

17 WIND ENERGY↗
DOE OSTI2021

Bamboo Bio-composite Truck/Trailer Decking

Bamboo is one of the fastest growing plants in the world. Massively productive, bamboo will maintain that productivity with limited inputs and minimal management resulting in predictable volume and operating margins and with low overhead. The goal of this project was to develop a bamboo bio-composite trailer decking product that replaces apitong, is lighter weight, stronger and luminescent. The collaboration partners, Fontaine, Resource Fiber and IACMI, worked closely to develop the bamboo bio-composite decking to Fontaine Trailer’s (end-user) specifications. The various technological objectives were (a) To conduct a comprehensive Design of Experiments study for bamboo composites to understand the structure-property relationships for different resin composites and bamboo forms (strips, woven, bulk etc); (b) To establish the nail pull out characteristics of trailer deck geometry bamboo composite form. The nail pull out is a critical test in trailer decks; (c) To design, process and prototype select number of trailer decking planks for Fontaine evaluation; and (d) To conduct life cycle analysis to conduct energy calculations from the various conversion steps of the bamboo from crop to product. The project meets DOE/IACMI metrics of reduced embodied energy, lightweighting and lowering the cost of the end product. It also offers a green solution to a value-added application, i.e. trailer decking. The development goals and benefits of bamboo composite decking included: A. Decreased weight when compared to Apitong and Gen 1, thereby reducing operating costs and petroleum usage due to increased miles per gallon. B. Flexibility to allow camber design into trailers. C. Luminescence to increase safety during low light and dark conditions. D. Composite material to maximize use of bamboo bio-composites as substitute for petroleum-based composites. E. Embedded layer(s) of conditioned bamboo for added strength and stability. F. Improved safety over Apitong by temporary cargo indentation in planks for better stability. G. Cradle-to-cradle design so end-of-life becomes beginning-of-life for other products. Resource Fiber’s bamboo biocomposite trailer decking passed nail pullout tests as compared to apitong (incumbent), was lighter weight than apitong, and used less embodied energy particularly when bamboo is sourced domestically. The planks were optimized in the lab setting to the extent possible and successfully installed on the trailer at Fontaine for field testing. Despite the process not being fully optimized due to through-heat and tooling limitations within the budget constraints, the prototype decking withstood 400 cycles of reverse fatigue loading of a 107,000 lb Caterpillar 349F which was extreme conditions of field testing by Fontaine Trailer. Resource Fiber plans to outsource production of a next round of planks with a commercial pultrusion processor, then to do a re-test with Fontaine Trailers. Tooling specific to the part is required. Long-term commercial plans are to continue outsourcing production while supplying bamboo fiber and mats. Commercial markets include heavy haul trailers, military trailers, and decking for marine, industrial and residential use.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Subcomponent Validation of Composite Joints for the Marine Energy Advanced Materials Project

The Marine Energy Advanced Materials project is an ongoing multi-year, multi-lab project with the main goals of addressing barriers and uncertainties facing marine energy developers in adopting advanced materials for structural applications. NREL's goals of the project were to address subcomponents testing needs for marine energy materials, to improve understanding of design allowables at the full-scale and provide near net-scale static and fatigue data of composite subcomponents using materials applicable to the marine energy industry. In the long term, the test method development and data generated would be used to inform standards development. This report outlines perhaps one of the largest-scale studies conducted with regards to saltwater conditioning of various composite material subcomponents and their subsequent structural validation, specifically directed at the marine renewable energy industry. A variety of fiberglass composite panels with epoxy and vinyl ester epoxy resin systems were manufactured at Montana State University, which were then used to manufacture an array of different types of subcomponent test specimens at the National Renewable Energy Laboratory's Flatirons Campus. These subcomponents were in the form of T-bolt and double-ended-insert specimens, which were intended to represent bonded and mechanical bolted connections for thick composite laminates, metal-metal and composite lap shear specimens to evaluate adhesion of constituent materials, and adhesive beam-shear specimens as part of an effort to better evaluate the characteristics of thick adhesive bondlines. Overall, the materials used were fiberglass reinforced epoxy and vinyl ester matrix composites, epoxy and methacrylate adhesives, and 316 and 2507 stainless steels. Specimens were then conditioned in salt water at various temperatures and for various periods of time at Florida Atlantic University and Pacific Northwest National Laboratory. All specimens were then mechanically characterized and validated using various test methods under static and fatigue loading conditions at NREL's Structural Technology Laboratory. Throughout the conditioning and mechanical validation process, valuable experience was gained, which will help guide future test method development for marine energy materials. In many instances, the results indicated similar observations as to what had been observed during previous coupon scale characterization efforts that provided a vital understanding of the scale up process. However in some instances, unexpected phenomena were observed, such as interactions between the adhesives and 316 steel. Furthermore, some materials exhibited significant degradation due to the saltwater conditioning. Ultimately, this report provides a detailed summary of the specimens that were designed, the subcomponent test methods that were developed, and the results that were generated, which will serve as important guidance for marine renewable energy developers and researchers for future structural designs and validation.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Wind Turbine Rotor Design Optimization Using Importance Sampling: Preprint

Probabilistic methods are commonly adopted to estimate both ultimate and fatigue loads in wind turbines, and multiple papers have presented a variety of approaches. In contrast, system-level, integrated design optimization methods for wind turbines have so far relied on deterministic methods to estimate loads and deflections. This work aims at addressing this gap by adopting importance sampling to estimate ultimate blade deflection for use within a rotor design optimization. A comparison between the results of this approach against traditional approaches using deterministic load evaluations show that the probabilistic approach is more conservative and that the solutions found with deterministic approaches violate the probabilistic constraint on tip deflection between 13% and 17%. This highlights the importance of accurate load and deflection estimates and demonstrates that probabilistic approaches can be successfully integrated within a wind turbine design process despite the higher computational costs.

17 WIND ENERGY↗
DOE OSTI2020

Power and Wind Shear Implications of Large Wind Turbine Scenarios in the US Central Plains

Continued growth of wind turbine physical dimensions is examined in terms of the implications for wind speed, power and shear across the rotor plane. High-resolution simulations with the Weather Research and Forecasting model are used to generate statistics of wind speed profiles for scenarios of current and future wind turbines. The nine-month simulations, focused on the eastern Central Plains, show that the power scales broadly as expected with the increase in rotor diameter (D) and wind speeds at hub-height (H). Increasing wind turbine dimensions from current values (approximately H = 100 m, D = 100 m) to those of the new International Energy Agency reference wind turbine (H = 150 m, D = 240 m), the power across the rotor plane increases 7.1 times. The mean domain-wide wind shear exponent (α) decreases from 0.21 (H = 100 m, D = 100 m) to 0.19 for the largest wind turbine scenario considered (H = 168 m, D = 248 m) and the frequency of extreme positive shear (α > 0.2) declines from 48% to 38% of 10-min periods. Thus, deployment of larger wind turbines potentially yields considerable net benefits for both the wind resource and reductions in fatigue loading related to vertical shear.

17 WIND ENERGY↗
DOE OSTI2024

Simulation of the Multi-Wake Evolution of Two Sandia National Labs/National Rotor Testbed Turbines Operating in a Tandem Layout

The future of wind power systems deployment is in the form of wind farms comprised of scores of such large turbines, most likely at offshore locations. Individual turbines have grown in span from a few tens of meters to today’s large turbines with rotor diameters that dwarf even the largest commercial aircraft. These massive dynamical systems present unique challenges at scales unparalleled in prior applications of wind science research. Fundamental to this effort is the understanding of the wind turbine wake and its evolution. Furthermore, the optimization of the entire wind farm depends on the evolution of the wakes of different turbines and their interactions within the wind farm. In this article, we use the capabilities of the Common ODE Framework (CODEF) model for the analysis of the effects of wake–rotor and wake-to-wake interactions between two turbines situated in a tandem layout fully and partially aligned with the incoming wind. These experiments were conducted in the context of a research project supported by the National Rotor Testbed (NRT) program of Sandia National Labs (SNL). Results are presented for a layout which emulates the turbine interspace and relative turbine emplacement found at SNL’s Scaled Wind Technologies Facility (SWiFT), located in Lubbock, Texas. The evolution of the twin-wake interaction generates a very rich series of secondary transitions in the vortex structure of the combined wake. These ultimately affect the wake’s axial velocity patterns, altering the position, number, intensity, and shape of localized velocity-deficit zones in the wake’s cross-section. This complex distribution of axial velocity patterns has the capacity to substantially affect the power output, peak loads, fatigue damage, and aeroelastic stability of turbines located in subsequent rows downstream on the farm.

Baruah, Apurva (ORCID:0000000252354068)↗
DOE OSTI2021

Results from a wake-steering experiment at a commercial wind plant: investigating the wind speed dependence of wake-steering performance

Wake steering is a wind farm control strategy in which upstream wind turbines are misaligned with the wind to redirect their wakes away from downstream turbines, thereby increasing the net wind plant power production and reducing fatigue loads generated by wake turbulence. In this paper, we present results from a wake-steering experiment at a commercial wind plant involving two wind turbines spaced 3.7 rotor diameters apart. During the 3-month experiment period, we estimate that wake steering reduced wake losses by 5.6% for the wind direction sector investigated. After applying a long-term correction based on the site wind rose, the reduction in wake losses increases to 9.3%. As a function of wind speed, we find large energy improvements near cut-in wind speed, where wake steering can prevent the downstream wind turbine from shutting down. Yet for wind speeds between 6–8 m/s, we observe little change in performance with wake steering. However, wake steering was found to improve energy production significantly for below-rated wind speeds from 8–12 m/s. By measuring the relationship between yaw misalignment and power production using a nacelle lidar, we attribute much of the improvement in wake-steering performance at higher wind speeds to a significant reduction in the power loss of the upstream turbine as wind speed increases. Additionally, we find higher wind direction variability at lower wind speeds, which contributes to poor performance in the 6–8 m/s wind speed bin because of slow yaw controller dynamics. Further, we compare the measured performance of wake steering to predictions using the FLORIS (FLOw Redirection and Induction in Steady State) wind farm control tool coupled with a wind direction variability model. Although the achieved yaw offsets at the upstream wind turbine fall short of the intended yaw offsets, we find that they are predicted well by the wind direction variability model. When incorporating the expected yaw offsets, estimates of the energy improvement from wake steering using FLORIS closely match the experimental results.

17 WIND ENERGY↗
DOE OSTI2022

Multifidelity multiobjective optimization for wake-steering strategies

Abstract. Wake steering is an emerging wind power plant control strategy where upstream turbines are intentionally yawed out of perpendicular alignment with the incoming wind, thereby “steering” wakes away from downstream turbines. However, trade-offs between the gains in power production and fatigue loads induced by this control strategy are the subject of continuing investigation. In this study, we present a multifidelity multiobjective optimization approach for exploring the Pareto front of trade-offs between power and loading during wake steering. A large eddy simulation is used as the high-fidelity model, where an actuator line representation is used to model wind turbine blades and a rainflow-counting algorithm is used to compute damage equivalent loads. A coarser simulation with a simpler loads model is employed as a supplementary low-fidelity model. Multifidelity Bayesian optimization is performed to iteratively learn both a surrogate of the low-fidelity model and an additive discrepancy function, which maps the low-fidelity model to the high-fidelity model. Each optimization uses the expected hypervolume improvement acquisition function, weighted by the total cost of a proposed model evaluation in the multifidelity case. The multifidelity approach is able to capture the logit function shape of the Pareto frontier at a computational cost only 30 % that of the single-fidelity approach. Additionally, we provide physical insights into the vortical structures in the wake that contribute to the Pareto front shape.

17 WIND ENERGY↗