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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗
NASA NTRS2012

Design and Performance Optimizations of Advanced Erosion-Resistant Low Conductivity Thermal Barrier Coatings for Rotorcraft Engines

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future rotorcraft engine higher fuel efficiency and lower emission goals. For thermal barrier coatings designed for rotorcraft turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability, because the rotorcraft are often operated in the most severe sand erosive environments. Advanced low thermal conductivity and erosion-resistant thermal barrier coatings are being developed, with the current emphasis being placed on thermal barrier coating toughness improvements using multicomponent alloying and processing optimization approaches. The performance of the advanced thermal barrier coatings has been evaluated in a high temperature erosion burner rig and a laser heat-flux rig to simulate engine erosion and thermal gradient environments. The results have shown that the coating composition and architecture optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic oxidation durability

Zhu, Dongming↗
NASA NTRS2011

Optimal Time Advance In Terminal Area Arrivals: Throughput vs. Fuel Savings

The current operational practice in scheduling air traffic arriving at an airport is to adjust flight schedules by delay, i.e. a postponement of an aircrafts arrival at a scheduled location, to manage safely the FAA-mandated separation constraints between aircraft. To meet the observed and forecast growth in traffic demand, however, the practice of time advance (speeding up an aircraft toward a scheduled location) is envisioned for future operations as a practice additional to delay. Time advance has two potential advantages. The first is the capability to minimize, or at least reduce, the excess separation (the distances between pairs of aircraft immediately in-trail) and thereby to increase the throughput of the arriving traffic. The second is to reduce the total traffic delay when the traffic sample is below saturation density. A cost associated with time advance is the fuel expenditure required by an aircraft to speed up. We present an optimal control model of air traffic arriving in a terminal area and solve it using the Pontryagin Maximum Principle. The admissible controls allow time advance, as well as delay, some of the way. The cost function reflects the trade-off between minimizing two competing objectives: excess separation (negatively correlated with throughput) and fuel burn. A number of instances are solved using three different methods, to demonstrate consistency of solutions.

Sadovsky, Alexander V .↗
NASA NTRS2002

Bioregenerative food system cost based on optimized menus for advanced life support

Optimized menus for a bioregenerative life support system have been developed based on measures of crop productivity, food item acceptability, menu diversity, and nutritional requirements of crew. Crop-specific biomass requirements were calculated from menu recipe demands while accounting for food processing and preparation losses. Under the assumption of staggered planting, the optimized menu demanded a total crop production area of 453 m2 for six crew. Cost of the bioregenerative food system is estimated at 439 kg per menu cycle or 7.3 kg ESM crew-1 day-1, including agricultural waste processing costs. On average, about 60% (263.6 kg ESM) of the food system cost is tied up in equipment, 26% (114.2 kg ESM) in labor, and 14% (61.5 kg ESM) in power and cooling. This number is high compared to the STS and ISS (nonregenerative) systems but reductions in ESM may be achieved through intensive crop productivity improvements, reductions in equipment masses associated with crop production, and planning of production, processing, and preparation to minimize the requirement for crew labor.

Non-NASA Center↗
DOE OSTI2024

Manufacturability-based optical design optimization for advanced Kirkpatrick–Baez X-ray focusing mirrors

The advanced Kirkpatrick–Baez (AKB) mirror setup is an effective and compelling solution to provide stable X-ray nano-focusing for synchrotron radiation or free-electron laser beamlines. We propose an AKB mirror design optimization approach to mitigate the difficulties associated with mirror fabrication by minimizing the total slope ranges of the four curved mirrors while achieving the expected focusing performance. In the optimization, we have considered geometry constraints to ensure the beam acceptance with the required clear aperture, the diffraction-limited focal size with the adequate numerical aperture, and the desired mirror gaps for adjustment and the necessary working distance for the sample stage. Additionally, practical constraints linked to mirror metrology and fabrication, such as mirror length limits and curvature uncertainty in measurement, are taken into account. Furthermore, progressive objective optimization eliminates the need for any initial guess, fully automating the AKB optimization process. This approach facilitates the development of an elegant Wolter-I or Wolter-III type AKB design solution that satisfies these multiple constraints. In cases where constraints cannot be simultaneously satisfied, the optimization results provide valuable insights into areas where trade-offs need to be considered. Simulations with ray tracing and wavefront propagation validate the optimized AKB design showing high tolerance to the beam incident angle.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Process Parameter Evaluation and Optimization for Advanced Material Development Final Report CRADA No. TC-1234-96

This project was established as a three-year collaboration to produce and characterize · silica aerogels prepared by a Rapid Supercritical Extraction (RSCE) process to meet . BNA, Inc. application requirements. The objectives of this project were to study the parameters necessary to produce optimized aerogel parts with narrowly specified properties and establish the range and limits of the process for producing such aerogels. The project also included development of new aerogel materials useful for high temperature applications. The results of the project were expected to set the conditions necessary to produce quantities of aerogels having particular specifications such as size, shape, density, and mechanical strength. BNA, Inc. terminated the project on April 7, 1999, 10-months prior to the anticipated completion date, due to termination of corporate funding for the project. The technical accomplishments achieved are outlined in Paragraph C below.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Optimization of Advanced Steels for Cyclic Operation through an Integration of Material Testing, Modeling and Novel Component Test Validation

The efforts in this project were focused in three primary objectives, provided below: • To develop the needed microstructural processing and performance relationships and associated material models for specific constituents in fabricated weldments (such as the parent material, heat affected zone regions and weld metal), • Apply these metallurgical relationships through modeling of a welded pressure bearing power plant component subjected to cyclic operational conditions under both mechanical and thermal loading, and • Validate the model through novel structural feature and component tests. An attempt was made to optimize the heat treatment schedule to reduce or eliminate the presence of boron nitride (BN) in the matrix of the Grade 92 material. BN has been shown to be a primary nucleation source for creep damage. Proper evaluation of material behavior, and as assessed in this research, included the influence of geometric notches (such as those from poor fabrication or design) and metallurgical notches (such as weldments or poorly processed parent material). Better practice methodologies were implemented in the theoretical design of a high-temperature, critical component for cyclic operation. It was demonstrated that vessel testing can be reliably performed and provides a critical link between standard testing, structural assessment and validation. While the goal of an improved Grade 92 steel was not achieved in this project, there is considerable value in applying the documented testing and assessment methodologies to assess material and/or component behavior. This is especially true for materials and/or designs which are expected to be subjected to flexible operating modes. Design of a cycling state of the art thick wall steam header for long term operation with a state of the art ferritic steel was a task in this project. Implementation of that task showed how many factors including plant operating mode, creep strength, creep ductility, fatigue strength, and resistance to crack growth should be considered and evaluated to properly design high temperature components for long term service (200,000 operating hours or more) in a modern Fossil energy power plant. The current ASME non-nuclear boiler design code does not mandate this level of complex analysis nor does it provide all the metallurgical and mechanical properties data needed to perform this kind of design analysis.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Techno-Economic Optimization of Advanced Energy Plants with Integrated Thermal, Mechanical, and Electro-Chemical Storage (Final Report)

The increasing use of renewable energy sources is leading to increased cycling of fossil-fueled power plants (FFPP) that are designed to operate at base-loaded conditions. Integrating energy storage facilities with the FFPPs can be helpful in reducing load-following operation of FFPPs. Decentralized deployment of energy storage facilities at the FFPP level has considerable advantages due to possibilities of smaller storage capacities, immediate benefits realized by the host power plant due to the increase in the efficiency, cleaner emission and higher plant life to name a few. Most importantly, deployment at the FFPP level can exploit the existing equipment items and facilities at the host power plant, thus reducing the CAPEX and reducing the storage capacity. However, realization of these benefits will critically depend on novel configuration/integration strategies with the least impact on the power plant operation and its configuration. Furthermore, dynamics of the entire integrated system including both the FFPP and the storage technologies must be taken into account to obtain the cost-optimal solution. With these motivations, the objective of this project was to complete a focused evaluation of decentralized deployments of energy storage facilities at the FFPP level. Promising thermal, chemical, mechanical, and electro-chemical storage technologies were evaluated with due consideration of their transient response to obtain various optimal system concepts that can minimize the levelized cost of storage. For thermal storage, cryogenic energy storage along with high temperature heat storage in molten salt as well as phase change material were evaluated. For mechanical storage, cryogenic air storage and pumped hydro storages were evaluated. For chemical storage, hydrogen storage was evaluated. For electrochemical storage, the team evaluated sodium sulfur, vanadium redox flow battery as well as Li-ion batteries. Integration of these storage technologies with the natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants was considered. Six technologies, namely molten salt, cryogenics, compressed air, pumped hydro, H2 storage and Li-ion battery storage, were downselected based on their levelized cost of storage. It was observed that the ranking of the optimal storage technology can differ based on the host power plant technology even when same demand/supply/price profile for electricity are considered. It was also observed that as the variability in power demand varies, the ranking of the optimal storage technologies vary. However, for the same demand and LMP profile, top six optimal storage technologies for NGCC vs SCPC plants did not differ much even though LCOS for the same technology and optimal size of a given storage technology did differ. Detailed techno-economic assessment of these six technologies was undertaken.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1990

Recent experience with multidisciplinary analysis and optimization in advanced aircraft design

The task of modern aircraft design has always been complicated due to the number of intertwined technical factors from the various engineering disciplines. Furthermore, this complexity has been rapidly increasing by the development of such technologies as aeroelasticity tailored materials and structures, active control systems, integrated propulsion/airframe controls, thrust vectoring, and so on. Successful designs that achieve maximum advantage from these new technologies require a thorough understanding of the physical phenomena and the interactions among these phenomena. A study commissioned by the Aeronautical Sciences and Evaluation Board of the National Research Council has gone so far as to identify technology integration as a new discipline from which many future aeronautical advancements will arise. Regardless of whether one considers integration as a new discipline or not, it is clear to all engineers involved in aircraft design and analysis that better methods are required. In the past, designers conducted parametric studies in which a relatively small number of principal characteristics were varied to determine the effect on design requirements which were themselves often diverse and contradictory. Once a design was chosen, it then passed through the various engineers' disciplines whose principal task was to make the chosen design workable. Working in a limited design space, the discipline expert sometimes improved the concept, but more often than not, the result was in the form of a penalty to make the original concept workable. If an insurmountable problem was encountered, the process began over. Most design systems that attempt to account for disciplinary interactions have large empirical elements and reliance on past experience is a poor guide in obtaining maximum utilizations of new technologies. Further compounding the difficulty of design is that as the aeronautical sciences have matured, the discipline specialist's area of research has generally narrowed as more sophisticated methods are developed in the specialist's area of expertise. The results have been a decrease in the awareness of the impact of his decisions on other disciplines. This paper will outline the progress and problems encountered in the analysis, design, optimization sensitivity analysis, mathematical modeling, and configurations control and the means by which they are being solved. The breadth versus depth dilemma in analysis and design and the means for coping with that dilemma will be discussed. Finally, the all-important human aspects and the need for a new 'culture ' for doing business in an integrated, multidisciplinary design environment are discussed.

Dollyhigh, Samuel M.↗
DOE OSTI2024

Optimization of the Second Target Station cold source moderators using an automated workflow

The Second Target Station (STS) at the US Department of Energy’s Oak Ridge National Laboratory is designed to become the world’s highest peak-brightness spallation source of cold neutrons. Successful completion of the STS, which is currently in the preliminary design phase, will provide transformative new capabilities to examine novel materials for future technologies. At STS, neutrons will be generated by spallation reactions in a solid tungsten target. They will be moderated and thermalized in two cold (20 K) para-hydrogen moderators. Careful optimization of these moderators is essential to the project’s success. To find optimal moderator designs, an advanced optimization workflow integrates high-fidelity neutronics calculations using the Monte Carlo N-Particle (MCNP) transport code MCNP6.2 with state-of-the-art optimization algorithms in the Dakota optimization toolkit. For each design iteration, a parametrized solid CAD geometry is generated in Creo and automatically converted into an unstructured mesh geometry by Attila 4MC for the neutronics calculation with MCNP. Iterations repeat until optimal designs are found. Herein this paper presents the results of a sensitivity and optimization study for the cylindrical and tube moderators. Both moderators can be optimized for maximum peak brightness, maximum time-integrated brightness, or any combination between these extremes. Maximum peak brightness is achieved by using smaller optimal dimensions of the moderators, whereas maximum time-integrated brightness is achieved by using larger dimensions. A Pareto front details the designs that optimally balance both brightness metrics. The Pareto front can be found in only 40–110 iterations with 4–5 design parameters when using the efficient global and Pareto-set optimization algorithms in Dakota. Additionally, important engineering constraints can be taken into account, such as the coupling between the cylindrical moderator radius and aluminum vessel wall thicknesses required to ensure structural integrity of the vessels. This interaction has a significant impact on the resulting optimal designs. Our new, highly efficient, fully automated optimization workflow will be used to optimize additional STS components in the future and can be adopted for design and optimization studies at other experimental neutron and accelerator facilities.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Advanced Method Optimization for Sampling and Analysis Instrumentation

This work presents a generalized approach for analytical method optimization that branches the gap between techniques historically employed and accurate modern optimization techniques suitable for various applications. The novelty of the described strategy is the utilization of multivariate, multiobjective optimization with Karush-Kuhn-Tucker conditions to bound the optimization space to solutions within the physical limitations of instrumentation. Briefly, the basic steps outlined in this paper are to (1) determine the objective(s) that should be maximized or minimized based on the goals of the analytical application, (2) conduct a screening experiment, (3) perform ANOVA to determine the parameters which have a statistically significant effect on the objective, (4) conduct an experiment (e.g., Box-Behnken design) to collect data for fitting the objective equation, and (5) determine the physical constraints of the parameters and solve the Lagrangian to determine the optimal method parameters. A broad approach to optimization target selection allows for robust method tuning to develop improved data sets amenable for chemometrics and machine learning algorithm development. Gas chromatography-mass spectrometry was selected as a use case due to its broad use across scientific fields and time-consuming method development involving numerous parameters. In conclusion, this strategy can reduce the cost of research, improve data quality, and enable the rapid development of new analytical technique.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

National Spherical Torus Experiment Upgrade Collaborative Research on Configuration Optimization of Advanced Operating Scenarios and Control Including Macroscopy Stability EOG for Period 3/1/14 through 2/28/18

General Atomics has collaborated with PPPL since 1999 in support of NSTX and NSXT-U by leveraging DIII-D program expertise. John Ferron was the principal investigator (PI) for the first nine years (to 2008) and Rob La Haye since then. The research effort evolved over a number of three-year grants and originally included both the core (control, stability, resonant error fields) and the boundary (ELMs, divertor, error fields). In 2014 the current and last grant extension was stretched to four years and split into a core grant (advanced scenarios and control, macroscopic plasma stability and extending 3D magnetics diagnostics) and a boundary grant. Todd Evans is the PI for the new boundary grant which while also for four years expires later than the core grant; a separate end of grant (EOG) report for that is due in July 2018.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1977

Advances in optimal routing through computer networks

The optimal routing problem is defined. Progress in solving the problem during the previous decade is reviewed, with special emphasis on technical developments made during the last few years. The relationships between the routing, the throughput, and the switching technology used are discussed and their future trends are reviewed. Economic aspects are also briefly considered. Modern technical approaches for handling the routing problems and, more generally, the flow control problems are reviewed.

Paz, I. M.↗
NASA NTRS1979

Procedure for noise prediction and optimization of advanced technology propellers

The sound field due to a propeller operating at supersonic tip speed in a uniform flow was investigated. Using the fact that the wave front in a uniform stream is a convected sphere, the fundamental solution to the convected wave equation was easily obtained. The Fourier coefficients of the pressure signature were obtained by a far field approximation, and are expressed as an integral over the blade platform. It is shown that cones of silence exist fore and aft the propeller plane. The semiapex angles are shown. These angles are independent of the individual Mach components such as the flight Mach number and the rotation Mach number. The result is confirmed by the computation of the ray path of the emitted Mach waves. The Doppler amplification factor strengthens the signal behind the propeller while it weakens that upstream.

Jou, W. H.↗
NASA NTRS1980

Application of an advanced trajectory optimization method to ramjet propelled missiles

The mission performance characteristics of ramjet-propelled missiles are highly dependent upon the trajectory flown. Integration of the trajectory profile with the ramjet propulsion system performance characteristics to achieve optimal missile performance is very complex. Past trajectory optimization methods have been extremely problem dependent and require a high degree of familiarity to achieve success. A general computer code (CTOP) has been applied to ramjet-powered missiles to compute open-loop optimal trajectories. CTOP employs Chebyshev polynomial representations of the states and controls. This allows a transformation of the continuous optimal control problem to one of parameter optimization. With this method, the trajectory boundary conditions are always satisfied. State dynamics and path constraints are enforced via penalty functions. The presented results include solutions to minimum fuel-to-climb, minimum time-to-climb, and minimum time-to-target intercept problems.

Paris, S. W.↗