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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Thermal Protection Systems↗
DOE OSTI2025

Tracking and Positioning System for Floating Solar (CRADA Abstract)

The project goal is to develop a floating solar photovoltaics (FPV) tracking & position system that: (1) increases annual energy production of FPV projects by >10%, (2) lowers levelized cost of energy (LCOE) for FPV by >10%, and (3) leverages U.S. contract supply chain & manufacturing. The outcome of the project will be a certified tracking product that has undergone extensive field testing and is ready for commercial sales. The primary objectives for each budget period are: • BP1: Define product requirements, develop initial controls architecture and design other sub-components, complete small-scale pilot testing, install a larger-scale pilot, secure sites for commercial pilots, and develop the beta-version of a user portal. • BP2: complete control system and sub-component design, successful demonstration and testing at a commercial pilot, certification & bankability, finalize user portal, and complete various commercialization activities related to supply chain, customer acquisition, and sales. PNNL will provide support during both project phases for prototype development and testing of the controls architecture, software, and hardware components of the tracking and positioning system. PNNL will provide support during both project phases for prototype development and testing of the controls architecture, software, and hardware components of the tracking and positioning system. This effort represents PNNL’s first opportunity to support the floating solar photovoltaics (FPV) industry with capabilities, facilities, and personnel developed to contribute to the marine energy (e.g., wave and tidal energy) sector. This portfolio expansion leverages internal and DOE EERE investments and the growing visibility of PNNL-Sequim’s Marine and Coastal Research Laboratory (MCRL) and our marine research capabilities, in general. The development of effective and low-cost FPV platforms is a potential way to increase the nation’s set of tools for providing emission-free electricity without utilizing valuable terrestrial resources. Successful commercialization of such a project may lead to economic benefits through job creation, supply chain creation, and access to a cheaper source of electricity.

14 SOLAR ENERGY↗
DOE OSTI2022

Characterizing manufacturing sector disruptions with targeted mitigation strategies

It has become clear in recent decades that manufacturing supply chains are increasingly vulnerable to disruptions of varying geographical scales and intensities. These disruptions—whether intentional, accidental, or resulting from natural disasters—cause failures and capacity reductions to manufacturing infrastructure, with lasting effects that can cascade throughout the manufacturing network. An overall lack of understanding of solutions to mitigate disturbances has rendered the challenge of reducing manufacturing supply chain vulnerability even more difficult. Additionally, the variability of disruptions and their impacts complicates policy maker and stakeholder efforts to plan for specific disruptive scenarios. It is necessary to comprehend different kinds of disturbances and group them based on stakeholder-provided metrics to support planning processes and modeling efforts that promote adaptable, resilient manufacturing supply chains. This paper reviews existing methods for risk management in manufacturing supply chains and the economic and environmental impacts of disruptions. In addition, we develop a framework using agglomerative hierarchical clustering to classify disruptions using U.S. manufacturing network data between 2000 and 2021 and characteristic metrics defined in the literature. Our review identifies five groups of disruptions and discusses both general mitigation methods and strategies targeting each identified group. Further, we highlight gaps in the literature related to estimating and including environmental costs in disaster preparedness and mitigation planning. We also discuss the lack of easily available metrics to quantify environmental impacts of disruptions and how such metrics could be included into our methodology.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗
DOE OSTI2020

Zincate-Blocking-Functionalized Polysulfone Separators for Secondary Zn–MnO 2 Batteries

Alkaline zinc–manganese dioxide (Zn–MnO 2 ) batteries are well suited for grid storage applications because of their inherently safe, aqueous electrolyte and established materials supply chain, resulting in low production costs. With recent advances in the development of Cu/Bi-stabilized birnessite cathodes capable of the full 2-electron capacity equivalent of MnO 2 (617 mA h/g), there is a need for selective separators that prevent zincate (Zn(OH) 4 ) 2– transport from the anode to the cathode during cycling, as this electrode system fails in the presence of dissolved zinc. In this work, we present the synthesis of N-butylimidazolium-functionalized polysulfone (NBI-PSU)-based separators and evaluate their ability to selectively transport hydroxide over zincate. We then examine their impact on the cycling of high depth of discharge Zn/(Cu/Bi–MnO 2 ) batteries when inserted in between the cathode and anode. Initially, we establish our membranes’ selectivity by performing zincate and hydroxide diffusion tests, showing a marked improvement in zincate-blocking (D Zn (cm 2 /min): 0.17 ± 0.04 × 10 –6 for 50-PSU, our most selective separator vs 2.0 ± 0.8 × 10 –6 for Cellophane 350P00 and 5.7 ± 0.8 × 10 –6 for Celgard 3501), while maintaining similar crossover rates for hydroxide (D OH (cm 2 /min): 9.4 ± 0.1 × 10 –6 for 50-PSU vs 17 ± 0.5 × 10 –6 for Cellophane 350P00 and 6.7 ± 0.6 × 10 –6 for Celgard 3501). We then implement our membranes into cells and observe an improvement in cycle life over control cells containing only the commercial separators (cell lifetime extended from 21 to 79 cycles).

crossover↗
NASA NTRSDate not supplied

Metal Additive Manufacturing for Spaceflight

Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.

Additive Manufacturing↗
DOE OSTI2020

Exploring the Next Generation of Low-Carbon Technologies for Deployment on Contaminated Lands

Low-carbon energy technologies and industries can reduce or avoid pollution, create economic development benefits (e.g. job creation), enhance local tax revenues, and support supply chain businesses. Many communities have vacant or underutilized and contaminated land that presents an opportunity cost for the economy and a blight on neighborhoods. This paper identifies a research agenda and funding proposal to support the next generation of low carbon technologies to deploy on contaminated lands.

brownfield sites↗
DOE OSTI2024

Securing Solar for the Grid: Spring 2024 IAB Meeting

The Spring 2024 IAB meeting will focus on updates from the research team and collective feedback and inputs for an updated Roadmap for Solar Cybersecurity. Researchers from the four DOE National Laboratories will present with industry counterparts for the major research tasks within the S2G program, including: Solar Cybersecurity Standards and Certifications, Solar Risk Assessments & Mitigation, Solar Supply Chain Assessment, Network Monitoring Tools and Analysis, and Training and Workforce Development. Sandia National Laboratories developed an original Roadmap for PV Cybersecurity in 2017. This year, we are updating that roadmap to reflect the current state of research and industry and identify gaps and priorities still to be addressed. We look forward to the IAB’s input on key topics for the roadmap.

14 SOLAR ENERGY↗
DOE OSTI2024

Profitability, Scalability and Optimized Siting for Waste-to-Energy Supply Chains: A Case Study on Hydrothermal Liquefaction

Waste-to-Energy (WtE) conversion technologies have the potential to simultaneously reduce waste volumes, treatment-related emissions, and carbon intensity while producing valuable energy services. However, questions remain regarding under which conditions emerging WtE technologies are feasible to deploy. In this project, we develop an optimized siting method for WtE technologies to assess cost-effective WtE processor locations, throughput scales, and profitability. We apply the model using Hydrothermal Liquefaction (HTL) as an example WtE technology. We develop calibrated capital and operating expense cost curves based on literature data to study the techno-economic characteristics of WtE supply chains. Prior to solving the siting optimization, we analyze the model parameters to describe organic waste management system behavior under four different HTL deployment configurations: Co-Processing, where HTL plants send biocrude to existing conventional refineries via assumed pipelines; Co-Location, where biorefineries are co-located with HTL plants; and two alternative Standalone Biorefining cases, where distributed HTL plants transport biocrude intermediate via either assumed pipelines or trucking to centralized biorefineries. We also define and apply several feedstock gate fee calculations, representing different revenue distribution options, to investigate how bioproduct value could impact WtE supply chain economics in terms of waste producer and processor profit or cost reduction.

09 BIOMASS FUELS↗
DOE OSTI2015

Opportunities and Challenges in the Design and Analysis of Biomass Supply Chains

The biomass supply chain is one of the most critical elements of large-scale bioenergy production and in many cases a key barrier for procuring initial funding for new developments on specific energy crops. Most productions rely on complex transforming chains linked to feed and food markets. The term 'supply chain' covers various aspects from cultivation and harvesting of the biomass, to treatment, transportation, and storage. After energy conversion, the product must be delivered to final consumption, whether it is in the form of electricity, heat, or more tangible products, such as pellets and biofuels. Effective supply chains are of utmost importance for bioenergy production, as biomass tends to possess challenging seasonal production cycles and low mass, energy and bulk densities. Additionally, the demand for final products is often also dispersed, further complicating the supply chain. The goal of this paper is to introduce key components of biomass supply chains, examples of related modeling applications, and if/how they address aspects related to environmental metrics and management. The paper will introduce a concept of integrated supply systems for sustainable biomass trade and the factors influencing the bioenergy supply chain landscape, including models that can be used to investigate the factors. Our paper will also cover various aspects of transportation logistics, ranging from alternative modal and multi-modal alternatives to introduction of support tools for transportation analysis. Lastly, gaps and challenges in supply chain research are identified and used to outline research recommendations for the future direction in this area of study.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Optimization and Comparison of Modern Offshore Wind Turbine Generators Using GeneratorSE 2.0

As the offshore wind industry keeps growing at a rapid pace, developers are bracing themselves for a huge demand in critical rare earth metals which will threaten an already vulnerable supply chain. The wind energy industry is addressing this problem by investing in modern generator technologies that employ magnets with reduced rare earth content and high-field magnets enabled by rare-earth-free superconductors. In this paper we introduce the National Renewable Energy Laboratory's newly advanced GeneratorSE 2.0, which is a design and optimization tool that was developed to investigate the feasibility of such modern generators. Two direct-drive generator topologies with different magnet materials and mounting arrangements are investigated: an outer-rotor, V-shaped interior permanent magnet generator, and an inner-rotor normally conducting armature, paired with a low-temperature superconducting field with race-track coils. These technologies were evaluated for a range of power ratings between 15 and 25 MW, which represent the next generation of offshore wind turbines for both fixed-bottom and floating applications. The analyses indicate a new trend favoring the low-temperature superconducting technology for the direct-drive system.

direct-drive generators↗
NASA NTRS2013

US Rocket Propulsion Industrial Base Health Metrics

The number of active liquid rocket engine and solid rocket motor development programs has severely declined since the "space race" of the 1950s and 1960s center dot This downward trend has been exacerbated by the retirement of the Space Shuttle, transition from the Constellation Program to the Space launch System (SLS) and similar activity in DoD programs center dot In addition with consolidation in the industry, the rocket propulsion industrial base is under stress. To Improve the "health" of the RPIB, we need to understand - The current condition of the RPIB - How this compares to past history - The trend of RPIB health center dot This drives the need for a concise set of "metrics" - Analogous to the basic data a physician uses to determine the state of health of his patients - Easy to measure and collect - The trend is often more useful than the actual data point - Can be used to focus on problem areas and develop preventative measures The nation's capability to conceive, design, develop, manufacture, test, and support missions using liquid rocket engines and solid rocket motors that are critical to its national security, economic health and growth, and future scientific needs. center dot The RPIB encompasses US government, academic, and commercial (including industry primes and their supplier base) research, development, test, evaluation, and manufacturing capabilities and facilities. center dot The RPIB includes the skilled workforce, related intellectual property, engineering and support services, and supply chain operations and management. This definition touches the five main segments of the U.S. RPIB as categorized by the USG: defense, intelligence community, civil government, academia, and commercial sector. The nation's capability to conceive, design, develop, manufacture, test, and support missions using liquid rocket engines and solid rocket motors that are critical to its national security, economic health and growth, and future scientific needs. center dot The RPIB encompasses US government, academic, and commercial (including industry primes and their supplier base) research, development, test, evaluation, and manufacturing capabilities and facilities. center dot The RPIB includes the skilled workforce, related intellectual property, engineering and support services, and supply chain operations and management. This definition touches the five main segments of the U.S. RPIB as categorized by the USG: defense, intelligence community, civil government, academia, and commercial sector.

Doreswamy, Rajiv↗
DOE OSTI2015

Model of the Product Development Lifecycle.

While the increased use of Commercial Off-The-Shelf information technology equipment has presented opportunities for improved cost effectiveness and flexibility, the corresponding loss of control over the product's development creates unique vulnerabilities and security concerns. Of particular interest is the possibility of a supply chain attack. A comprehensive model for the lifecycle of hardware and software products is proposed based on a survey of existing literature from academic, government, and industry sources. Seven major lifecycle stages are identified and defined: (1) Requirements, (2) Design, (3) Manufacturing for hardware and Development for software, (4) Testing, (5) Distribution, (6) Use and Maintenance, and (7) Disposal. The model is then applied to examine the risk of attacks at various stages of the lifecycle.

He, Sunny L.↗
DOE OSTI2015

Supply Chain Sustainability Analysis of Fast Pyrolysis and Hydrotreating Bio-Oil to Produce Hydrocarbon Fuels

The Department of Energy’s (DOE) Bioenergy Technology Office (BETO) aims at developing and deploying technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of technologies to produce biofuels. These assessments evaluate feedstock production, logistics of transporting the feedstock, and conversion of the feedstock to biofuel. There are two general types of TEAs. A design case is a TEA that outlines a target case for a particular biofuel pathway. It enables preliminary identification of data gaps and research and development needs, and provides goals and targets against which technology progress is assessed. On the other hand, a state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual experimental results relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to the TEA process, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for more than 17 years. It enables BETO to identify energy consumption or environmental issues that may be associated with biofuel production. Approaches to mitigate these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO’s research and development portfolio. This report describes the SCSA of the fast pyrolysis of two woody feedstocks, pine and forest residue, to renewable gasoline and diesel.

09 BIOMASS FUELS↗
NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗
NASA NTRSDate not supplied

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗
DOE OSTI2026

Enhanced Validation of Advanced Battery Supply Chains (EVALS) Overview

EVALS is a consortium funded by the Vehicle Technologies Office at DOE involving Idaho National Lab, Argonne National Lab, and NREL. The goal of EVALS is to fully develop a suite of tools that support domestic electric vehicle manufacturing through evaluation of domestic primary resources and acceleration of their path to domestic material and battery production. This talk will focus on describing the EVALS project and discussing initial results regarding domestic LiFePO4 precursor sourcing and impacts on the domestic manufacturing supply chain.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2012

Forestry Biofuel Statewide Collaboration Center (Michigan) (Final Technical Report)

A team composed of scientists from Michigan State University (MSU) and Michigan Technological University (MTU) assembled to better understand, document, and improve systems for using forest-based biomass feedstocks in the production of energy products within Michigan. Work was funded by a grant (DE-EE-0000280) from the U.S. Department of Energy (DOE) and was administered by the Michigan Economic Development Corporation (MEDC). The goal of the project was to improve the forest feedstock supply infrastructure to sustainably provide woody biomass for biofuel production in Michigan over the long-term. Work was divided into four broad areas with associated objectives: • TASK A: Develop a Forest-Based Biomass Assessment for Michigan – Define forest-based feedstock inventory, availability, and the potential of forest-based feedstock to support state and federal renewable energy goals while maintaining current uses. • TASK B: Improve Harvesting, Processing and Transportation Systems – Identify and develop cost, energy, and carbon efficient harvesting, processing and transportation systems. • TASK C: Improve Forest Feedstock Productivity and Sustainability – Identify and develop sustainable feedstock production systems through the establishment and monitoring of a statewide network of field trials in forests and energy plantations. • TASK D: Engage Stakeholders – Increase understanding of forest biomass production systems for biofuels by a broad range of stakeholders. The goal and objectives of this research and development project were fulfilled with key model deliverables including: 1) The Forest Biomass Inventory System (Sub-task A1) of feedstock inventory and availability and, 2) The Supply Chain Model (Sub-task B2). Both models are vital to Michigan’s forest biomass industry and support forecasting delivered cost, as well as carbon and energy balance. All of these elements are important to facilitate investor, operational and policy decisions. All other sub-tasks supported the development of these two tools either directly or by building out supporting information in the forest biomass supply chain. Outreach efforts have, and are continuing to get these user friendly models and information to decision makers to support biomass feedstock supply chain decisions across the areas of biomass inventory and availability, procurement, harvest, forwarding, transportation and processing. Outreach will continue on the project website at http://www.michiganforestbiofuels.org/ and http://www.michiganwoodbiofuels.org/

09 BIOMASS FUELS↗