Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “advanced construction methods”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19

(Invited) All-Solid-State Batteries Using Li 7 La 3 Zr 2 O 12 Garnet Electrolyte Framework

All-solid-state batteries (ASSB) using LLZO (variants of Li 7 La 3 Zr 2 O 12 ) garnet solid electrolyte with lithium metal anode potentially offer higher energy density and improved safety. Rational design of cell architecture as well as manufacturing scalability are key aspects to consider as the technology readiness level advances. A thick composite cathode layer attached to a thin solid electrolyte layer is desirable to obtain superior energy densities. Furthermore, the architecture within the composite cathode may be engineered to contain directional conduction paths of lithium ions or electrons for enhanced rate capabilities. Here, we demonstrate a functioning bulk-type LLZO based all-solid-state battery with a practical form factor incorporating the above described design concepts. Freeze-tape-casting (FTC), a scalable and environmentally friendly ceramic processing method, is used to construct 3D porous LLZO scaffolds composed of vertical arrays of LLZO walls. The thin solid-electrolyte layer is fabricated by tape-casting (TC). By sintering the stacks of FTC and TC green tapes, porous/dense bilayers and porous/dense/porous trilayers of LLZO frameworks are obtained. An ASSB was constructed using a porous/dense bilayer by infiltrating LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathode powder and carbon black into the porous layer and adhering lithium metal foil to the dense side. We find it crucial to introduce a plastic crystal based soft solid electrolyte to the porous layer to electrochemically connect all cathode components, obviating the need for co-sintering to establish contact. The soft nature of the plastic crystal based solid-electrolyte may be able to accommodate the volume change of the cathode material as it cycles. In this device, which contained no liquid component, the initial discharge capacities were similar to those observed in a lithium ion battery configuration using the same cathode powder at C/10 rates.

25 ENERGY STORAGE↗

Structures Protection

Materials of which an aircraft is made and the methods used to hold these materials together forming the aircraft structure were studied as factors important in protecting a modern aircraft from hazardous natural environments. Since all-metal aircraft are being replaced by aircraft constructed partly of fiber reinforced plastics with desirable light weight and high strength properties but with poor electrical conductivity, the danger of lightning strikes has become more serious. Lightning effects on metal structures were reviewed and design protection was discussed. The expected lightning effects on nonmetallic materials such as fiberglass and advanced composites were also reviewed.

Franklin A Fisher↗

Binary Black Holes, Gravitational Waves, and Numerical Relativity

The final merger of two black holes releases a tremendous amount of energy and is one of the brightest sources in the gravitational wave sky. Observing these sources with gravitational wave detectors requires that we know the radiation waveforms they emit. Since these mergers take place in regions of extreme gravity, we need to solve Einstein's equations of general relativity on a computer in order to calculate these waveforms. For more than 30 years, scientists have tried to compute these waveforms using the methods of numerical relativity. The resulting computer codes have been plagued by instabilities, causing them to crash well before the black holes in the binary could complete even a single orbit. This situation has changed dramatically in the past year, with a series of amazing breakthroughs. This talk will take you on this quest for the holy grail of numerical relativity, showing how a spacetime is constructed on a computer to build a simulation laboratory for binary black hole mergers. We will focus on the recent advances that are revealing these waveforms, and the dramatic new potential for discoveries that arises when these sources will be observed by LISA and LIGO.

Centrella, Joan↗

Design and Analysis Tools for Supersonic Inlets

Computational tools are being developed for the design and analysis of supersonic inlets. The objective is to update existing tools and provide design and low-order aerodynamic analysis capability for advanced inlet concepts. The Inlet Tools effort includes aspects of creating an electronic database of inlet design information, a document describing inlet design and analysis methods, a geometry model for describing the shape of inlets, and computer tools that implement the geometry model and methods. The geometry model has a set of basic inlet shapes that include pitot, two-dimensional, axisymmetric, and stream-traced inlet shapes. The inlet model divides the inlet flow field into parts that facilitate the design and analysis methods. The inlet geometry model constructs the inlet surfaces through the generation and transformation of planar entities based on key inlet design factors. Future efforts will focus on developing the inlet geometry model, the inlet design and analysis methods, a Fortran 95 code to implement the model and methods. Other computational platforms, such as Java, will also be explored.

Slater, John W.↗

An Introduction to Transient Engine Applications Using the Numerical Propulsion System Simulation (NPSS) and MATLAB

This document outlines methodologies designed to improve the interface between the Numerical Propulsion System Simulation framework and various control and dynamic analyses developed in the Matlab and Simulink environment. Although NPSS is most commonly used for steady-state modeling, this paper is intended to supplement the relatively sparse documentation on it's transient analysis functionality. Matlab has become an extremely popular engineering environment, and better methodologies are necessary to develop tools that leverage the benefits of these disparate frameworks. Transient analysis is not a new feature of the Numerical Propulsion System Simulation (NPSS), but transient considerations are becoming more pertinent as multidisciplinary trade-offs begin to play a larger role in advanced engine designs. This paper serves to supplement the relatively sparse documentation on transient modeling and cover the budding convergence between NPSS and Matlab based modeling toolsets. The following sections explore various design patterns to rapidly develop transient models. Each approach starts with a base model built with NPSS, and assumes the reader already has a basic understanding of how to construct a steady-state model. The second half of the paper focuses on further enhancements required to subsequently interface NPSS with Matlab codes. The first method being the simplest and most straightforward but performance constrained, and the last being the most abstract. These methods aren't mutually exclusive and the specific implementation details could vary greatly based on the designer's discretion. Basic recommendations are provided to organize model logic in a format most easily amenable to integration with existing Matlab control toolsets.

Matlab↗

Reconfigurable Cellular Composite Structures for Lighter than Air Vehicles with Scalable Size and Endurance

Engineered non-stochastic cellular materials show promising characteristics on the laboratory scale,with nearly ideal specific stiffness and strength scaling at ultralight mass density. These propertiessuggest performance benefits in any application with combined stiffness and mass constraints, suchas air vehicles. We investigate here the application of re-configurable cellular composite materialsand structures to lighter than air vehicles. We describe the properties and applicability of these materials,provide an example analysis of governing loading conditions associated with airships, showan example optimization method for navigating the design space, and describe how recent advancesin cellular material manufacturing and reconfiguration enable system performance benefits includingnew concepts of operation. Lastly, we propose lighter than air vehicles that are assembled andmaintained in-flight, eliminating structural compromises associated with transitional flight modesand ground handling.Engineered non-stochastic cellular material properties suggest performance benefits in lighter than air vehicles due tostiffness and mass constraints that are intrinsic to the airship design problem. Recent advances in cellular materialmanufacturing and reconfiguration enable system performance benefits including new concepts of operation, such aslighter than air vehicles that are assembled and maintained in-flight, eliminating structural compromises associatedwith transitional flight modes and ground handling. Existing engineered cellular materials display properties allowinglarge large scale airships design as monocoque cellular solids. Inevitable improvements in cellular material propertiesand manufacturing will improve feasibility even further. Given the suggestion that the two most significant technologygaps exist across all current airship projects are manufacturing and assembly processes and ground handling [7],a strategy that encompasses construction and maintenance in flight could provide critical rephrasing of the systemdesign problem through these new concepts of operation. Refactoring of traditional manufacturing, operation, andservice process constraints could extend to other domains in aerospace systems and manufacturing in general.In future work, the complexity of the design task would benefit from a form of optimization in order to find themost suitable geometry for a chosen application. For example, the Sequential Least SQuares Programming (SLSQP)function from within the SciPy Minimize library is a multiobjective constrained optimization method that has beenapplied to fixed wing aircraft design. [17] In this situation it would allow for several objective functions such as drag,bending stiffness, buoyancy and cost of transport to be incorporated into a composite objective function.

Copplestone, Grace↗

Hypersonic flow computations around re-entry vehicles

The development of an algorithm for the solution of the compressible Euler equations at high Mach numbers on unstructured tetrahedral meshes is described. The basic algorithm is constructed in the form of a central difference scheme plus an explicit added artificial viscosity based upon fourth order differences of the solution. The stability of the solution in the vicinity of strong gradients is preserved by the incorporation of an additional artificial viscosity based upon a second order difference. Higher order accuracy is regained by using the ideas of flux corrected transport to limit the amount of added viscosity. The solution is advanced to steady state by means of an explicit multi-stage time-stepping method. The computational efficiency of the complete process is improved by incorporating an unstructured multigrid acceleration procedure. A number of flows of practical interest are analyzed to demonstrate the numerical performance of the proposed approach.

Peraire, J.↗

Stereo-vision thermal imaging system for tracking flying animals in wind farm areas (CRADA #763) Abstract

CRADA 763: abstract ThermalTracker-3D (TT3D) is a stereo vision thermal imaging system that provides 3D flight information on detected birds, bats, and other flying targets. The system was initially developed for use in the siting and monitoring of offshore wind projects to establish pre-construction and operation collision risk data but can be applied to terrestrial wind energy projects as well as national security monitoring. This technology will reduce monitoring cost, decrease processing time, and provide more accurate data for wind energy developers/operators and regulatory agencies. While the current technology is at a high level of readiness, Technology Readiness Level (TRL) 7, there remain several barriers to commercialization, particularly around ease-of-use, that result in a low Adoption Readiness Level (ARL). The proposed work will advance commercialization readiness by streamlining calibration methods for built systems. This work will:1. 1. develop a software package for factory and dynamic calibration processes 2. test that package with existing prototype TT3D systems, and 3. conduct outreach with industry end-users.

ThermalTracker↗

Probabilistic Multi-Scale, Multi-Level, Multi-Disciplinary Analysis and Optimization of Engine Structures

Aircraft engines are assemblies of dynamically interacting components. Engine updates to keep present aircraft flying safely and engines for new aircraft are progressively required to operate in more demanding technological and environmental requirements. Designs to effectively meet those requirements are necessarily collections of multi-scale, multi-level, multi-disciplinary analysis and optimization methods and probabilistic methods are necessary to quantify respective uncertainties. These types of methods are the only ones that can formally evaluate advanced composite designs which satisfy those progressively demanding requirements while assuring minimum cost, maximum reliability and maximum durability. Recent research activities at NASA Glenn Research Center have focused on developing multi-scale, multi-level, multidisciplinary analysis and optimization methods. Multi-scale refers to formal methods which describe complex material behavior metal or composite; multi-level refers to integration of participating disciplines to describe a structural response at the scale of interest; multidisciplinary refers to open-ended for various existing and yet to be developed discipline constructs required to formally predict/describe a structural response in engine operating environments. For example, these include but are not limited to: multi-factor models for material behavior, multi-scale composite mechanics, general purpose structural analysis, progressive structural fracture for evaluating durability and integrity, noise and acoustic fatigue, emission requirements, hot fluid mechanics, heat-transfer and probabilistic simulations. Many of these, as well as others, are encompassed in an integrated computer code identified as Engine Structures Technology Benefits Estimator (EST/BEST) or Multi-faceted/Engine Structures Optimization (MP/ESTOP). The discipline modules integrated in MP/ESTOP include: engine cycle (thermodynamics), engine weights, internal fluid mechanics, cost, mission and coupled structural/thermal, various composite property simulators and probabilistic methods to evaluate uncertainty effects (scatter ranges) in all the design parameters. The objective of the proposed paper is to briefly describe a multi-faceted design analysis and optimization capability for coupled multi-discipline engine structures optimization. Results are presented for engine and aircraft type metrics to illustrate the versatility of that capability. Results are also presented for reliability, noise and fatigue to illustrate its inclusiveness. For example, replacing metal rotors with composites reduces the engine weight by 20 percent, 15 percent noise reduction, and an order of magnitude improvement in reliability. Composite designs exist to increase fatigue life by at least two orders of magnitude compared to state-of-the-art metals.

Chamis, Christos C.↗

Spaceborne Passive-Microwave Hail Detection: Global Climatologies, Validation, and Challenges Going Forward

In addition to the myriad threats that severe hailstorms pose to society, infrastructure and agriculture, severe hail is difficult to measure in situ, and surface-based hail reporting and detection methods are inconsistent and vulnerable to nonmeteorological biases. This motivates the use of spaceborne remote-sensing platforms to retrieve hail and construct climatologies in a globally uniform way. We have developed a hail detection algorithm that leverages the sensitivity of spaceborne passive-microwave radiometers to scattering by hail, particularly in the channels from 10 to 89 GHz. We use this retrieval to construct global passive-microwave climatologies of severe hail using the Tropical Rainfall Measuring Mission (TRMM) Microwave Imager (TMI), Global Precipitation Measurement Mission (GPM) Microwave Imager, Advanced Microwave Scanning Radiometer for EOS (AMSR-E), and Advanced Microwave Scanning Radiometer 2 (AMSR2) sensors and are working to extend into the pre-TRMM era to the Special Sensor Microwave Imager/Sounder (SSMI/(S)) data. Using coincident Global Precipitation Measurement (GPM) Ku-band precipitation radar, we assessed this retrieval and several others in the literature for their effectiveness and regional variability. We find that this retrieval, which leverages a signature in the Minimum 19-GHz polarization corrected temperature (PCT) combined with the 37-GHz PCT depression normalized by tropopause height constrains the radar reflectivity most tightly, and gives the least appearance of regional biases compared to other passive-microwave approaches in the literature. Satellite platforms offer consistent observations, even in remote, data-sparse, and oceanic regions that ground-based networks exclude. There are, however, potential disconnects between the processes identified aloft by the satellite and the resultant weather at the ground, leading to uncertainties in the retrievals that may propagate into satellite-based climatologies, particularly in the Tropics, where there are abundant strong - but not necessarily hailing - storms that are strongly represented in the current satellite climatologies. We will discuss ongoing efforts to assess and mitigate the contributing factors to these uncertainties, chiefly among them the effects of non-uniform beam filling in the passive-microwave footprint, and the relationships between the size distributions of hailstones aloft and the dynamic processes and environments with which they interact throughout their trajectories.

Sarah D. Bang↗

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗

A Technology Roadmap for Advanced Geothermal Well Construction

Recent analysis has shown that by 2050, geothermal energy can supply up to 90 GW of power to the U.S. electrical grid. Reducing the lifecycle cost of geothermal wells is critical to achieving this level of adoption. While time-related costs of drilling remain an important issue, there is also a need to focus on the costs associated with casing and cementing of geothermal wells. This report provides a roadmap of R&D activities needed to reduce the life cycle cost of casing and cementing while improving life-of-well performance. The purpose of the roadmap is to develop priorities for R&D in the areas of (1) high-performance and cost-effective materials for target geothermal well conditions, (2) well construction methods and techniques to reduce construction costs, and (3) methods and techniques to decrease to decrease long-term operating costs. The roadmap sets targets for the next 10-year period and purposely excludes R&D efforts into improved rock reduction. The roadmap was developed by a joint working group of experts from Oak Ridge National Laboratory, Brookhaven National Laboratory, and Sandia National Laboratories as well as 35 experts from industry and academia. Input from a series of information gathering sessions was used to inform and guide the development of the roadmap.

15 GEOTHERMAL ENERGY↗

Cradle-to-gate life cycle assessment of advanced composite panels incorporating CO 2 -derived multi-walled carbon nanotubes and hemp fiber for sustainable building applications

Advanced composite panels represent a promising pathway to reducing carbon emissions in the construction industry, yet comprehensive environmental impact assessments remain limited. Here, in this study, we conduct a life cycle assessment (LCA) to evaluate the environmental impacts of innovative composite panels produced from multi-walled carbon nanotubes (MWCNTs), hemp fiber (HF), recycled carbon fiber (rCF), and recycled polypropylene (PP), exploring their potential as baseline structural equivalents to conventional gypsum board. MWCNTs and HF play a critical role in sequestering carbon during raw material production, while the recycling processes for CF and PP generally require less energy compared to virgin material production. The LCA evaluates environmental performance using the TRACI 2.1 method, covering global warming potential (GWP), ozone depletion, smog formation, acidification, eutrophication, carcinogenic and non-carcinogenic effects, respiratory impacts, ecotoxicity, and fossil fuel depletion. Compositional variations—resin type (virgin vs. recycled), rCF content (9–29 wt%), and HF content (10–30 wt%)—are introduced for sensitivity and hotspot analyses. Results demonstrate that, when compared on the basis of preliminary structural equivalence, increasing recycled PP, rCF, and HF content can significantly reduce global warming potential compared to gypsum board. Beyond carbon reduction, the composite panels show trade-offs across other environmental categories. With the growing demand for composite materials in interior panels, ceiling systems, and exterior claddings, these findings highlight the environmental benefits and potential trade-offs of the proposed composites, establishing a foundational framework to support their continued development toward full building-system integration.

Advanced composite manufacturing↗

Parameterization and Explicit Modeling of Cloud Microphysics: Approaches, Challenges, and Future Directions

Cloud microphysical processes occur at the smallest end of scales among cloud-related processes and thus must be parameterized not only in large-scale global circulation models (GCMs) but also in various higher-resolution limited-area models such as cloud-resolving models (CRMs) and large-eddy simulation (LES) models. Instead of giving a comprehensive review of existing microphysical parameterizations that have been developed over the years, this study concentrates purposely on several topics that we believe are understudied but hold great potential for further advancing bulk microphysics parameterizations: multi-moment bulk microphysics parameterizations and the role of the spectral shape of hydrometeor size distributions; discrete vs “continuous” representation of hydrometeor types; turbulence-microphysics interactions including turbulent entrainment-mixing processes and stochastic condensation; theoretical foundations for the mathematical expressions used to describe hydrometeor size distributions and hydrometeor morphology; and approaches for developing bulk microphysics parameterizations. Also presented are the spectral bin scheme and particle-based scheme (especially, super-droplet method) for representing explicit microphysics. Their advantages and disadvantages are elucidated for constructing cloud models with detailed microphysics that are essential to developing processes understanding and bulk microphysics parameterizations. Particle-resolved direct numerical simulation (DNS) models are described as an emerging technique to investigate turbulence-microphysics interactions at the most fundamental level by tracking individual particles and resolving the smallest turbulent eddies in turbulent clouds. Outstanding challenges and future research directions are explored as well.

54 ENVIRONMENTAL SCIENCES↗

Deep Learning Provides Substantial Improvements to County‐Level Fire Weather Forecasting Over the Western United States

Abstract The recent wildfires in the western United States during 2018 and 2020 caused record‐breaking fire damage and casualties. Despite remarkable advances in fire modeling and weather forecasting, it remains challenging to anticipate catastrophic wildfire events and associated damage. One key missing component is a fire weather prediction system with sufficiently long lead time capable of providing useful regional details. Here, we develop a hybrid prediction model of wildfire danger called CFS with super resolution (CFS‐SR) as a proof of concept to fill that void. The CFS‐SR model is constructed by integrating the Climate Forecast System version 2 with a deep learning (DL) technique from Single Image Super Resolution, a method widely used in enhancing image resolution. We show that for the 2018–2019 fire season, the CFS‐SR model significantly improves accuracy in forecasting fire weather at lead times of up to 7 days with an enhanced spatial resolution up to 4 km. This level of high resolution provides county‐level fire weather forecast, making it more practical for allocating resources to mitigate wildfire danger. Our study demonstrates that a proper combination of ensemble climate predictions with DL techniques can boost predictability at finer spatial scales, increasing the utility of fire weather forecasts for practical applications.

54 ENVIRONMENTAL SCIENCES↗

Enhancing the Q-Factor of a Practical Qubit Niobium Three-Dimensional λ/4-Resonator Through Surface Treatment

Quantum computing stands as a revolutionary frontier in information technology, with the potential to solve complex problems far beyond the capacity of classical computers. At the heart of this disruptive innovation are qubits, forming the fundamental backbone of quantum computing. A leading-edge solution for constructing robust, enduring qubits involves embedding a Josephson junction within a high Q-factor, superconducting three-dimensional cavity. Further, our recent innovation lies in developing a uniquely optimized, quarter-wave resonator-based superconducting cavity, functioning at 6 GHz, specifically tailored for quantum computers. In this work, we elucidate our advancement towards elevating the Q-factor tenfold, an achievement made possible through the enhancement of machining precision, the application of rigorous postprocessing techniques—including mechanical, chemical, and surface treatments—as well as the refinement of our testing methods.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Tokamak Disruption Simulation (Final Technical Report)

The Tokamak Disruption Simulation collaboration was a SciDAC (Scientific Discovery through Advanced Computing) program led by Xianzhu Tang of the Los Alamos National Laboratory but with separate grants to each institution. I was the PI for Columbia University and the only person at Columbia directly funded by this SciDAC. Disruptions are a sudden loss of confinement in tokamaks, and a reliable method of preventing disruptions must be developed before tokamak fusion power plants become feasible. A related plasma confinement concept, the stellarator, is the only way known way of preventing disruptions with the required reliability. The largest devices, both existing and under construction, for confining plasmas for fusion using magnetic fields are tokamaks, so it is important to solve their disruption issues. The sudden loss of confinement in tokamaks can be from a bit of material falling into the plasma, which causes the plasma energy to be quickly lost by radiation, or by an instability causing a breakup of the confining surfaces formed by the magnetic field. This breakup can occur more than a million times faster than one would naively think possible. The sudden breakup of surfaces is called a fast magnetic reconnection and also results in a sudden cooling of the plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Feasibility Assessment of Using Electrical Impedance Tomography for Damage Localization in Graphite Microreactor Components

Microreactors have great potential to decrease capital costs and construction timelines, reducing the barriers to implementing advanced nuclear reactor technologies. However, the lower power output of these microreactors introduces economic challenges if the operation and maintenance costs cannot be reduced sufficiently. Many microreactor concepts use graphite materials for in-core moderator and structural purposes, which will require periodic inspection or, ideally, in situ structural health monitoring. This work describes an initial evaluation of the feasibility of leveraging graphite’s semiconducting properties to perform electrical impedance tomography (EIT) for defect localization. First, a study was performed to identify the best methods for bonding electrical contacts to minimize the effects of contact resistance that interfere with impedance measurements of the graphite. After determining the best bonding approach, electrodes were attached to multiple graphite components with varying geometries (e.g., simple block and more representative microreactor hexagonal block). In parallel, finite element analysis approaches were developed and implemented to analyze the impact of defects and contact resistances and to inform an iterative inverse model for reconstructing the conductivity distribution. The results of this study show that defect localization in graphite components is possible using EIT if a sufficient number of electrodes (to improve spatial resolution) can be bonded using a technique with very low contact resistance and those contact resistances remain stable during reactor operation. If the reactor core and vessel design do not allow electrodes to be bonded during reactor operation, then it may be possible to detach/reattach electrodes between reactor operation and outages if a suitable mechanical connection that offers repeatable contact resistance can be identified. Alternatively, future work could focus on identifying contacts that can survive the harsh reactor operating environment so that contacts do not need to be removed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗