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DOE OSTI2017

3D printing technologies for electrochemical energy storage

Fabrication of electrodes and electrolytes play an important role in promoting the performance of electrochemical energy storage (EES) devices such as batteries and supercapacitors. Traditional fabrication techniques have limited capability in controlling the geometry and architecture of the electrode and solid-state electrolytes, which would otherwise compromise the performance. 3D printing, a disruptive manufacturing technology, has emerged as an innovative approach to fabricating EES devices from nanoscale to macroscale and from nanowatt to megawatt, providing great opportunities to accurately control device geometry (e.g., dimension, porosity, morphology) and structure with enhanced specific energy and power densities. Moreover, the additive manufacturing nature of 3D printing provides excellent controllability of the electrode thickness with much simplified process in a cost effective manner. With the unique spatial and temporal material manipulation capability, 3D printing can integrate multiple nanomaterials in the same print, and multi-functional EES devices (including functional gradient devices) can be fabricated. Herein, we review recent advances in 3D printing of EES devices. We focused on two major 3D printing technologies including direct writing and inkjet printing. The direct material deposition characteristics of these two processes enable them to print on a variety of flat substrates, even a conformal one, well suiting them to applications such as wearable devices and on-chip integrations. Other potential 3D printing techniques such as freeze nano-printing, stereolithography, fused deposition modeling, binder jetting, laminated object manufacturing, and metal 3D printing are also introduced. The advantages and limitations of each 3D printing technology are extensively discussed. More importantly, we provide a perspective on how to integrate the emerging 3D printing with existing technologies to create structures over multiple length scale from macro to nano for EES applications.

3D printing↗

DOE OSTI2025

Coordinated Frequency Regulation in Grid-Forming Storage Network via Safety-Consensus

Inverter-based storages are poised to play a prominent role in future power grid with massive renewable generation. Grid-forming inverters (GFMs) are emerging as a dominant technology with synchronous generators (SG)-like characteristics through primary control loops. Advanced secondary-layer control schemes, e.g., consensus algorithms, allow GFM-interfaced storage units to participate in frequency regulations and restore nominal frequency following grid disturbances. However, it is imperative to ensure critical frequency safety limits are not violated while the grid transitions from pre- to post-disturbance operating point. This paper presents a novel safety-enforced consensus method, having three distinct objectives: safe transient frequency evolution, minimizing frequency deviation, and coordinated power sharing. The proposed technique is illustrated using a GFM-interfaced grid-wide storage network on the IEEE 68-bus system under multiple grid transient scenarios.

consensus control↗

NASA NTRS1996

Holographic Vibration Testing With Video/Computer Imaging

In improved system for holographic vibration testing, holographic interferograms indicating shapes of vibrational modes recorded by video camera under computer control. Results available almost immediately, and images distributed simultaneously to multiple computer terminals connected to vibration-testing computer via local-area network. Designed to replace prior photography-based system for identifying natural vibrational modes of propfan blades; adaptable to similar vibration testing of other objects.

Miller, Christopher J.↗

NASA NTRS2003

Generative Representations for Evolving Families of Designs

Since typical evolutionary design systems encode only a single artifact with each individual, each time the objective changes a new set of individuals must be evolved. When this objective varies in a way that can be parameterized, a more general method is to use a representation in which a single individual encodes an entire class of artifacts. In addition to saving time by preventing the need for multiple evolutionary runs, the evolution of parameter-controlled designs can create families of artifacts with the same style and a reuse of parts between members of the family. In this paper an evolutionary design system is described which uses a generative representation to encode families of designs. Because a generative representation is an algorithmic encoding of a design, its input parameters are a way to control aspects of the design it generates. By evaluating individuals multiple times with different input parameters the evolutionary design system creates individuals in which the input parameter controls specific aspects of a design. This system is demonstrated on two design substrates: neural-networks which solve the 3/5/7-parity problem and three-dimensional tables of varying heights.

Hornby, Gregory S.↗

NASA NTRS2011

Mount Protects Thin-Walled Glass or Ceramic Tubes from Large Thermal and Vibration Loads

The design allows for the low-stress mounting of fragile objects, like thin walled glass, by using particular ways of compensating, isolating, or releasing the coefficient of thermal expansion (CTE) differences between the mounted object and the mount itself. This mount profile is lower than true full kinematic mounting. Also, this approach enables accurate positioning of the component for electrical and optical interfaces. It avoids the higher and unpredictable stress issues that often result from potting the object. The mount has been built and tested to space-flight specifications, and has been used for fiber-optic, optical, and electrical interfaces for a spaceflight mission. This mount design is often metal and is slightly larger than the object to be mounted. The objects are optical or optical/electrical, and optical and/or electrical interfaces are required from the top and bottom. This requires the mount to be open at both ends, and for the object s position to be controlled. Thin inside inserts at the top and bottom contact the housing at defined lips, or edges, and hold the fragile object in the mount. The inserts can be customized to mimic the outer surface of the object, which further reduces stress. The inserts have the opposite CTE of the housing material, partially compensating for the CTE difference that causes thermal stress. A spring washer is inserted at one end to compensate for more CTE difference and to hold the object against the location edge of the mount for any optical position requirements. The spring also ensures that any fiber-optic or optic interface, which often requires some pressure to ensure a good interface, does not overstress the fragile object. The insert thickness, material, and spring washer size can be traded against each other to optimize the mount and stresses for various thermal and vibration load ranges and other mounting requirements. The alternate design uses two separate, unique features to reduce stress and hold the object. A release agent is applied to the inside surface of the mount just before the binding potting material is injected in the mount. This prevents the potting material from bonding to the mount, and thus prevents stress from being applied, at very low temperatures, to the fragile object being mounted. The potting material mixing and curing is temperature- and humidity-controlled. The mount has radial grooves cut in it that the potting material fills, thus controlling the vertical position of the mounted object. The design can easily be used for long and thin objects, short and wide objects, and any shape in between. The design s advantages are amplified for long and thin fragile objects. The general testing range was 45 to +45 C, but multiple mounts were successfully tested down to 60 and up to 50 C and the design can be adjusted for larger ranges.

Amato, Michael↗

NASA NTRS2005

Advanced Three-Dimensional Display System

A desktop-scale, computer-controlled display system, initially developed for NASA and now known as the VolumeViewer(TradeMark), generates three-dimensional (3D) images of 3D objects in a display volume. This system differs fundamentally from stereoscopic and holographic display systems: The images generated by this system are truly 3D in that they can be viewed from almost any angle, without the aid of special eyeglasses. It is possible to walk around the system while gazing at its display volume to see a displayed object from a changing perspective, and multiple observers standing at different positions around the display can view the object simultaneously from their individual perspectives, as though the displayed object were a real 3D object. At the time of writing this article, only partial information on the design and principle of operation of the system was available. It is known that the system includes a high-speed, silicon-backplane, ferroelectric-liquid-crystal spatial light modulator (SLM), multiple high-power lasers for projecting images in multiple colors, a rotating helix that serves as a moving screen for displaying voxels [volume cells or volume elements, in analogy to pixels (picture cells or picture elements) in two-dimensional (2D) images], and a host computer. The rotating helix and its motor drive are the only moving parts. Under control by the host computer, a stream of 2D image patterns is generated on the SLM and projected through optics onto the surface of the rotating helix. The system utilizes a parallel pixel/voxel-addressing scheme: All the pixels of the 2D pattern on the SLM are addressed simultaneously by laser beams. This parallel addressing scheme overcomes the difficulty of achieving both high resolution and a high frame rate in a raster scanning or serial addressing scheme. It has been reported that the structure of the system is simple and easy to build, that the optical design and alignment are not difficult, and that the system can be built by use of commercial off-the-shelf products. A prototype of the system displays an image of 1,024 by 768 by 170 (=133,693,440) voxels. In future designs, the resolution could be increased. The maximum number of voxels that can be generated depends upon the spatial resolution of SLM and the speed of rotation of the helix. For example, one could use an available SLM that has 1,024 by 1,024 pixels. Incidentally, this SLM is capable of operation at a switching speed of 300,000 frames per second. Implementation of full-color displays in future versions of the system would be straightforward: One could use three SLMs for red, green, and blue, respectively, and the colors of the voxels could be automatically controlled. An optically simpler alternative would be to use a single red/green/ blue light projector and synchronize the projection of each color with the generation of patterns for that color on a single SLM.

Geng, Jason↗

NASA NTRS1989

A development framework for distributed artificial intelligence

The authors describe distributed artificial intelligence (DAI) applications in which multiple organizations of agents solve multiple domain problems. They then describe work in progress on a DAI system development environment, called SOCIAL, which consists of three primary language-based components. The Knowledge Object Language defines models of knowledge representation and reasoning. The metaCourier language supplies the underlying functionality for interprocess communication and control access across heterogeneous computing environments. The metaAgents language defines models for agent organization coordination, control, and resource management. Application agents and agent organizations will be constructed by combining metaAgents and metaCourier building blocks with task-specific functionality such as diagnostic or planning reasoning. This architecture hides implementation details of communications, control, and integration in distributed processing environments, enabling application developers to concentrate on the design and functionality of the intelligent agents and agent networks themselves.

Adler, Richard M.↗

DOE OSTI2025

Uncertainty quantification and sensitivity analysis of a nuclear thermal propulsion reactor startup sequence

The research presented in this article describes progress in applying stochastic methods, uncertainty quantification, parametric studies, and variance-based sensitivity analysis (also known as Sobol sensitivity analysis) to a full-core model of a nuclear thermal propulsion (NTP) system simulated via the radiation transport code Griffin to simulate neutronics. Our goal is to develop a reduced-order (surrogate) model that can be rapidly sampled with perturbations to multiple input parameters. In this NTP system, reactivity and power feedback affect the rotation of control drums (CDs), which is itself controlled by a hybrid proportional-integral-derivative (PID) controller actuated by the power demand and reactivity feedback from the numerical model. This model uses reactor kinetic feedback (mean generation time [Λ] and effective delayed neutron fraction [ β eff ] from a transient Griffin simulation executed via Griffin’s improved quasi-static solver to provide the kinetic parameters) as inputs to functions that control the CD rotation angle. By investigating numerous stochastic approaches, we developed a dual-purpose surrogate model of the NTP system, using polynomial regression in the Multiphysics Object-Oriented Simulation Environment (MOOSE) Stochastic Tools Module (STM). The trained model can be rapidly sampled while simultaneously perturbing various input parameters, such as coefficients on the PID control or temperature (directly affecting the neutron cross section). The surrogate model delivers accurate (within 5%) results at speeds orders of magnitude faster (minutes, not days of computational time) than the base model. Once the surrogate model has been trained, distributions of the uncertain parameters can be changed at will to investigate the effects of perturbing multiple inputs as well as the effects of these inputs on the model output. For example, coefficients used in the PID control system may vary due to some type of physical interference, or uncertainty may exist in the temperature of the neutron cross sections in various regions of the reactor. A distribution can be placed on these parameters, and operational boundaries can be determined. The goal of this work is to support development of an advanced control system for operating CDs in a functioning NTP system. This work is a scoping study of the MOOSE STM.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2023

IDAES-PSE 2.0 Release

The Institute for the Design of Advanced Energy Systems (IDAES) Integrated Platform is a versatile computational environment offering extensive process systems engineering (PSE) capabilities for optimizing the design and operation of complex, interacting technologies and systems. IDAES enables users to efficiently search vast, complex design spaces to discover the lowest cost, most environmentally sustainable solutions while supporting the full process modeling lifecycle, from conceptual design to dynamic optimization and control. The extensible, open platform empowers users to create models of novel processes and rapidly develop custom analyses, workflows, and end-user applications. IDAES-PSE 2.0.0 Release Highlights Removal of deprecated features from IDAES v1 Update to Pyomo v6.5 – this required a number of updates to support the new NL solver writer and to address some changes in Pyomo Creation of new testing suite for backward compatibility, model robustness and verification More general implementation of the Helmholtz EoS. This brings some new features like standard property diagrams, choice of mass or mole basis, and new state variable options Standardizing names in Heat Exchanger models (breaking change from v2.0.0a2): Control Volumes named hot_side and cold_side Ports names hot_side_inlet, hot_side_outlet, cold_side_inlet and cold_side_outlet Config Blocks names hot_side_config and cold_side_config Config arguments for user provided names for each side: hot_side_name and cold_side_name. Updating Keras surrogate tool to use v1.1 of OMLT New prototype API for model initialization (idaes.core.initialization) The new API uses "Model Initializer" objects instead of class methods, allowing for the definition of multiple initialization routines for a single model A number of common, model agnostic initialization routines have also been defined, including initialization from data, block-decomposition and a general hierarchical approach equivalent to the existing method for common unit models New metadata for thermophysical properties – valid_range This can be used to record the range of values over which a property value can be trusted, such as the range of experimental data used to regress parameters A number of new utility functions have been added to check for properties with values outside the valid range and to set bounds based on this metadata Updated construction of balance expressions in Control Volumes to remove unneeded terms In the past, unneeded terms were added as a constant 0 term, however they will now be dropped entirely from the expression This was necessary due to more strict unit checking in the new Pyomo solver writer which no longer ignores 0 terms Updates to metadata for thermophysical properties to better define known properties and units of measurement This results in more strict enforcement of standard naming for thermophysical and reaction properties Users can still define custom properties, but these must be done explicitly using the define_custom_properties() method instead of being implicitly created by add_property() Updated convergence tester utility tool to support definition of benchmark files (JSON format) and comparison of performance to benchmarks Set default iteration limit for IPOPT in IDAES config to 200 iterations Update scaling of example models to work with new Pyomo NL solver writer Improve testing of extensions and examples infrastructure to avoid need for downloading files Updated distillation column to centralize common functionality and remove a number of Pyomo warnings

IDAES↗

DOE OSTI2017

Combustion energy frontier research center (CEFRC) final report (August 1, 2009 – July 31, 2016)

The Combustion Energy Frontier Research Center (CEFRC) was established to tackle the single overarching grand challenge of energy sustainability, energy security and global warming: to develop a “validated, predictive, multi-scale, combustion modeling capability to optimize the design and operation of evolving fuels in advanced engines for transportation applications,” as identified in the DOE report on “Basic Energy Needs for Clean and Efficient Combustion of 21st Century Transportation Fuels”. The challenge is particularly daunting since energy conversion efficiencies and exhaust emissions are governed by coupled chemical and transport processes at multiple length scales ranging from electron excitation to molecular rearrangements to nanoscale particulate formation to turbulent fuel/air mixing. To tackle this challenge, the CEFRC assembled a world-class team of 15 principal investigators, with the objectives to: 1) develop and test theoretical models to predict elementary reaction rates, molecule thermalization rates, chemical bond dissociation energies, and nonequilibrium transport properties using quantum chemistry calculations that account for strong electron correlation and multiple electronic potential energy surfaces; 2) develop automated kinetic mechanism generation, reduction, and error control methods for predicting alternative fuel including biofuel oxidation, fuel droplet decomposition, and NOx and particulate formation; 3) validate and improve the predictions of these models by measuring ignition delay times, species profiles, flame structures, burning limits, turbulence-kinetic coupling, and NOx and soot emissions at high-pressures and near-limit conditions, by using advanced experimental diagnostic techniques including multiple laser techniques, molecular beam sampling and synchrotron photoionization, and by conducting the measurements in high-pressure shock tubes, jet-stirred and flow reactors, flame bombs, counterflow flames, and advanced-design rapid compression ignition instruments; and 4) develop a suite of validated petascale high-fidelity simulation and modeling capabilities to understand and predict chemistry-turbulence-radiation coupling for new fuels in new regimes, including the high pressure, low-temperature combustion in advanced engine and turbine designs, and 5) establish a knowledge highway between researchers and engineers in academia, national laboratories, and industry to facilitate the dissemination and exchange of knowledge on national and international levels, and enrich the talent pool and capabilities of the next generation of combustion scientists and engineers. The technical activities of the CEFRC were conducted through three Disciplinary Working Groups – Chemistry Theory, Experiment and Mechanism, and Reacting Flows, which coordinated the Center’s research on the development of combustion chemistry of Foundation Fuels (C0–C4 hydrocarbons), Alcohols, and Biodiesel through three corresponding Mechanism Thrust Groups. Such a two-dimensional coordinated and tightly interwoven research structure has been proven to be highly effective in assuring the interplay between the developments of the fundamentals of combustion science and the utilization of the various categories of fuels. The Center has accomplished the above goals over the five year period (August 1, 2009 – July 31, 2014) with appropriated funding, followed by two additional no-cost-extension (NCE) years. The research results are documented in 230 journal publications, with six legacy review papers on the study of combustion chemistry using shock tubes, flow reactors, rapid compression machines, and flames, on uncertainty quantification, and on theoretical reaction dynamics and chemical modeling of combustion. A robust outreach program complemented these PI-led research activities, consisting of: 1) a roving post-doc program comprised of a corps of Center-appointed, co- or multi-sponsored post-doctoral fellows with rotating assignments to conduct seed projects initiated by at least two PIs, in residence with these sponsoring PIs, to rapidly pursue new and high-risk, high-payoff interdisciplinary ideas; 2) an annual summer school on combustion heavily attended (~200) by senior graduate students and practicing researchers covering advanced topics on chemical kinetics, fluid mechanics, turbulent combustion, engine combustion, new technologies, etc.; 3) a robust open web-site providing Center and community information as well as the lecture videos and notes of the summer school; and 4) widely distributed biannual newsletters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Scale up, Field testing, and Optimization of Nontoxic, Durable, Economical Coatings for Control of Biofouling and Corrosion (Abstract Only)

The objective of this project is the technical maturation and demonstration of a durable, economical, and nontoxic coating, Superhydrophobic Lubricant Infused Composite (SLIC), that will prevent fouling organisms from growing on marine and hydrokinetic (MHK) structures and prevent invasive mussels from growing on hydropower structures. SLIC technology was developed and patented by PNNL. It combines multiple antifouling mechanisms to provide excellent antifouling performance, durability, and low hydrodynamic drag without using toxic materials. Advanced proof-of-concept testing and demonstrations completed during a Phase 1 TCF project attracted industry interest and partnerships for this Phase 2 effort focused on maturation of a commercial product. Specific tasks and tests will shift the development emphasis to optimizing formulations, validating antifouling performance to address specific application needs, explore compatibility with other paint systems, develop a product with useful shelf life (in can), and determine curing times and effective applications methodology. Phase 2 efforts will focus upon technology transfer and commercialization of the technology with the industrial team. Industrial partners now include a coatings development specialist (Lorama), hydrophobic material manufacturer and paint developer (Dry Surface Technologies), nontoxic biodegradable lubricants manufacturer (BioBlend), and aquatic applications specialists (Prometheus Innovations, River Connectivity Systems). Engagement with the MHK device developers, the PNNL Marine and Coastal Research Laboratory (MCRL) test site in Sequim WA, Bureau of Reclamation, and Taylor Shellfish throughout the project will provide topical expertise and field test sites that will deliver crucial real-world performance data. Through this Phase 2 effort, SLIC will transition from a Technical Readiness Level (TRL) 5 to TRL 6 and long-term performance data will be acquired through demonstrations. The field test data will allow optimization of SLIC formulation to enhance performance (e.g., durability) and packaging, which are key de-risking activities for technology transfer and ultimately to the production of a viable commercial product.

13 HYDRO ENERGY↗

NASA NTRS1989

Characterization of fluid flow by digital correlation of scattered light

The objective is to produce a physical system suitable for a space environment that can measure fluid velocities in a three-dimensional volume by the development of a particle correlation velocimetry technique. Experimental studies were conducted on a field test cell to demonstrate the suitability and accuracy of digital correlation techniques for measuring two-dimensional fluid flows. This objective was satisfied by: (1) the design of an appropriate illumination and detection system for making velocity measurements within a test cell; (2) the design and construction of a test cell; (3) the preliminary evaluations on fluid and seeding requirements; and (4) the performance of controlled tests using a multiple exposure correlation technique. This presentation is represented by viewgraphs with very little text.

Gilbert, John A.↗

NASA NTRS2005

Software for Engineering Simulations of a Spacecraft

Spacecraft Engineering Simulation II (SES II) is a C-language computer program for simulating diverse aspects of operation of a spacecraft characterized by either three or six degrees of freedom. A functional model in SES can include a trajectory flight plan; a submodel of a flight computer running navigational and flight-control software; and submodels of the environment, the dynamics of the spacecraft, and sensor inputs and outputs. SES II features a modular, object-oriented programming style. SES II supports event-based simulations, which, in turn, create an easily adaptable simulation environment in which many different types of trajectories can be simulated by use of the same software. The simulation output consists largely of flight data. SES II can be used to perform optimization and Monte Carlo dispersion simulations. It can also be used to perform simulations for multiple spacecraft. In addition to its generic simulation capabilities, SES offers special capabilities for space-shuttle simulations: for this purpose, it incorporates submodels of the space-shuttle dynamics and a C-language version of the guidance, navigation, and control components of the space-shuttle flight software.

Shireman, Kirk↗

DOE OSTI2025

ForceFinder

SAND2025-11750O ForceFinder extends the Structural Dynamics Python Libraries (SDynPy) with comprehensive tools for inverse source estimation (ISE) tasks via frequency response function (FRF) matrix inversion. The software is designed for transfer path analysis and multiple-input/multiple-output (MIMO) vibration control problems. It allows users to estimate sources through various algorithms, from the basic Moore-Penrose pseudo-inverse to statistical learning methods such as Tikhonov regularization via an L-curve and elastic net regularization via an information criterion. ForceFinder uses an object-oriented framework, where all components of the ISE problem—such as FRFs, responses, and transformations—are stored in a "SourcePathReceiver" object. This software can be applied to any noise and vibration problem. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Carter, Steven [Sandia National Lab. (SNL-CA), Liv↗

DOE OSTI2019

Innovative Dual Fuel Aftermarket Emissions Solution

The objective of this project was to develop an advanced emission control system for Class 7 and 8 heavy-duty dual-fuel vehicles that eliminate or mitigates the negative effects of currently used diesel particulate filters (DPF) and selective catalytic reduction (SCR) emissions-treatment systems. The project combined multiple technologies that worked together to increase engine efficiency and reduce most emissions from the combustion process.

42 ENGINEERING↗

NASA NTRS1973

Acoustic processing method for MS/MS experiments

Acoustical methods in which intense sound beams can be used to control the position of objects are considered. The position control arises from the radiation force experienced when a body is placed in a sound field. A description of the special properties of intense sound fields useful for position control is followed by a discussion of the more obvious methods of position, namely the use of multiple sound beams. A new type of acoustic position control device is reported that has advantages of simplicity and reliability and utilizes only a single sound beam. Finally a description is given of an experimental single beam levitator, and the results obtained in a number of key levitation experiments.

Whymark, R. R.↗

NASA NTRS1976

Passenger comfort during terminal-area flight maneuvers

A series of flight experiments was conducted to obtain passenger subjective responses to closely controlled and repeatable flight maneuvers. In 8 test flights, reactions were obtained from 30 passenger subjects to a wide range of terminal-area maneuvers, including descents, turns, decelerations, and combinations thereof. Analysis of the passenger rating variance indicated that the objective of a repeatable flight passenger environment was achieved. Multiple linear regression models developed from the test data were used to define maneuver motion boundaries for specified degrees of passenger acceptance.

Schoonover, W. E., Jr.↗

NASA NTRS1979

A regression technique for evaluation and quantification for water quality parameters from remote sensing data

The objective of this paper is to define optical physics and/or environmental conditions under which the linear multiple-regression should be applicable. An investigation of the signal-response equations is conducted and the concept is tested by application to actual remote sensing data from a laboratory experiment performed under controlled conditions. Investigation of the signal-response equations shows that the exact solution for a number of optical physics conditions is of the same form as a linearized multiple-regression equation, even if nonlinear contributions from surface reflections, atmospheric constituents, or other water pollutants are included. Limitations on achieving this type of solution are defined.

Whitlock, C. H.↗