Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Component sizing”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Collection of fluorescence from an ion using trap-integrated photonics

Spontaneously emitted photons are entangled with the electronic and nuclear degrees of freedom of the emitting atom, so interference and measurement of these photons can entangle separate matter-based quantum systems as a resource for quantum information processing. Since confinement in a single-mode facilitates the photon interference needed for generating entanglement, the dipole emission patterns relevant in spontaneous emission present a mode-matching challenge. Current demonstrations rely on bulk photon-collection and manipulation optics that suffer from large component size and system-to-system variability—factors that impede scaling to the large numbers of entangled pairs needed for quantum information processing. To address these limitations, we demonstrate a collection method that enables passive phase stability, straightforward photonic manipulation, and intrinsic reproducibility. Specifically, we engineer a waveguide-integrated grating to couple photons emitted from a trapped ion into a single optical mode within a microfabricated ion-trap chip. Using the integrated collection optic, we characterize the collection efficiency, image the ion, and detect the ion’s quantum state. The integrated optic covers 2.18% of the solid angle and collects 1.97 ± 0.3% of the spontaneously emitted light incident on the grating for a total collection efficiency of 0.043% into a single-mode waveguide. This proof-of-principle demonstration lays the foundation for leveraging the inherent stability and reproducibility of integrated photonics to create, manipulate, and measure multipartite quantum states in arrays of quantum emitters.

Optical physics↗
DOE OSTI2024

Design of the cryogenic moderator system for the second target station

The Second Target Station (STS) at Oak Ridge National Laboratory will be a 700 kW pulsed spallation neutron source designed to provide the world's highest brightness cold neutron beams. In order to produce the required neutron performance, two compact liquid hydrogen moderators are located adjacent to the tungsten spallation target and must be supplied with less than 20 K hydrogen and a para hydrogen fraction of 99.8% or greater. The Cryogenic Moderator System (CMS) will consist of a single hydrogen loop feeding the two moderators in series cooled by a helium refrigerator with a cooling capacity of 2.5 kW at 17 K. The hydrogen loop consists of a hydrogen circulator, hydrogen helium heat exchanger, ortho-para converter, accumulator, transfer lines and heater. The design of the hydrogen loop is based on the CMS design of the First Target Station at the Spallation Neutron Source and some of the component designs may be reused. General hydrogen temperature control is provided by controlling the flowrate of helium to the heat exchanger. The hydrogen loop will have a constant flowrate of 0.5 L/s and remove a nuclear heat load of about 850 W from the two moderators, which is deposited both directly in the hydrogen and the adjacent hydrogen containing structures. Because the nuclear heat load is accelerator driven, the hydrogen system must remain stable when the heat load is removed instantaneously during beam trips. System stability is maintained passively with the accumulator and actively with the heater. Ionizing radiation which interacts with the liquid hydrogen drives backconversion of the hydrogen from parahydrogen to orthohydrogen. The STS moderator performance is very sensitive to small fractions of orthohydrogen requiring an ortho-para converter to maintain the hydrogen supplied to the moderators at near equilibrium parahydrogen concentration. STS CMS is in the early stage of preliminary design and current focus is evaluating component sizing and system stability during beam transients.

Janney, Jim↗
DOE OSTI2023

Open Circuit Switch Fault Management Method of a Multi-Phase Synchronous Buck Converter for EV Charging Application

Multi-phase synchronous buck converter (MSBC) is becoming popular for the electric vehicle (EV) charging application because of its higher efficiency, smaller passive component sizes, bidirectional power flow, and output current ripple reduction through interleaving. This converter also provides higher reliability than the traditional single phase converter since its modular structure enables fault tolerant operation. Fault management in the converter requires the detection of switch fault, shut down of the faulty phase, and reconfiguration of the PWM signals for the healthy phases to avoid circulating current and high output current ripple. In addition, it is desirable that the fault management method can be implemented using the micro-controller unit (MCU) or digital signal processor (DSP), which are widely used to control power converters. This paper presents a fault management method for detecting switch faults and reconfiguring healthy phases using a DSP. The method is validated through simulations and experiments using a commercial off-the-shelf power stack.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Recovery of Glass and Silicon Solar Cells from Si-Modules Through Laser Processing

This study demonstrates an innovative and environmentally friendly laser-based approach for the efficient recovery of glass and silicon solar cells, allowing the recycling of photovoltaic modules. The methodology involves the use of a high-power pulsed laser beam focusing at various interfaces within the modules. Specifically, the delivery of ultra-short pulse laser energy at the interfaces of glass and polymeric encapsulants, as well as at the encapsulants and silicon solar cells, facilitates the debonding of polymers from both glass and silicon cell surfaces. The debonding occurs through photothermal, ablation, chemical modification, and localized heat generation. The research successfully demonstrates the recovery of glass from commercial mini solar modules of size 11.5 x 6.8 cm 2 and a silicon wafer of size 3.0x1.6 cm 2 . Ongoing efforts aim to extend the effectiveness of this laser-based methodology to comprehensively recycle larger-size components. This innovative approach holds promise for addressing environmental concerns associated with the disposal of solar modules, contributing to sustainable practices in the renewable energy sector.

glass↗
DOE OSTI2022

SCHOTT laser glass [Invited]

Laser glass is a highly engineered optical material that enables the amplification of light in laser systems. It is known for being the heart of the largest laser facilities ever built, where thousands of neodymium-doped meter-sized slabs of laser glass create intense beams of near-infrared laser radiation used to study fusion reactions. Or if doped with ytterbium and erbium, laser glass can be made into millimeter-sized components empowering range-finders and dermatological lasers. Decades of development have poised laser glass for the next challenge on the horizon: amplifying light for sustainable inertial fusion energy power plants.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Assessment of Heavy-Duty Fueling Methods and Components-Modeling and Analysis

The goal of the Assessment of Heavy-Duty Fueling Methods and Components project was to comprehensively assess heavy-duty (HD) fuel cell electric vehicle fueling protocols and their effects on techno-economic assessments (TEA) and total cost of ownership (TCO). The project leveraged and built upon ongoing international HD fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, TEA of industry-selected protocol structures, and experimental validations of the strategies at the station scale. The effects of the protocols on the fueling times, station costs, and TCO were explored. Fueling time, which was influenced by temperature and protocol selection, had a large impact on the station cost due to component sizing and satisfying hourly demand. As the fleet size increased, the station cost was shown to exponentially decrease by achieving economies of scale. Technology year and fuel economy were the largest contributors to the TCO; however, the choice of fueling protocol had a minor impact on the TCO.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Optimal Control and Architecture Design Optimization for Hydraulic Drive Train of a Compact Track Loader

Hydrostatic transmission (HST) is a common hydraulic drive train transmission used in track loaders and other high power off-road vehicles. While reliable, traditional HST with fixed-displacement motors has relatively poor efficiencies. In this paper, alternative HST and series hybrid drive train architectures are proposed to replace the traditional HST to allow the implementation of optimal control and optimization methods for better vehicle fuel efficiency. Besides the optimal control methods applied to minimize fuel consumption, the proposed architectures are also optimized for the best configuration in terms of component sizing. Backward-facing (acausal) simulation models were developed to estimate the fuel efficiency of each architecture. Finally, each architecture is compared for optimized performance and fuel saving relative to the traditional HST as baseline.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Techno-Economic Analysis of a Concentrating Solar Power Plant Using Redox-Active Metal Oxides as Heat Transfer Fluid and Storage Media

We present results for a one-dimensional quasi-steady-state thermodynamic model developed for a 111.7 MW e concentrating solar power (CSP) system using a redox-active metal oxide as the heat storage media and heat transfer agent integrated with a combined cycle air Brayton power block. In the energy charging and discharging processes, the metal oxide CaAl 0.2 Mn 0.8 O 2.9-δ (CAM28) undergoes a reversible, high temperature redox cycle including an endothermic oxygen-releasing reaction and exothermic oxygen-incorporation reaction. Concentrated solar radiation heats the redox-active oxide particles under partial vacuum to drive the reduction extent deeper for increased energy density at a fixed temperature, thereby increasing storage capacity while limiting the required on sun temperature. Direct counter-current contact of the reduced particles with compressed air from the Brayton compressor releases stored chemical and sensible energy, heating the air to 1,200°C at the turbine inlet while cooling and reoxidizing the particles. The cool oxidized particles recirculate through the solar receiver subsystem for another cycle of heating and reduction (oxygen release). We applied the techno-economic model to 1) size components, 2) examine intraday operation with varying solar insolation, 3) estimate annual performance characteristics over a simulated year, 4) estimate the levelized cost of electricity (LCOE), and 5) perform sensitivity analyses to evaluate factors that affect performance and cost. Simulations use hourly solar radiation data from Barstow, California to assess the performance of a 111.7 MW e system with solar multiples (SMs) varying from 1.2 to 2.4 and storage capacities of 6–14 h. The baseline system with 6 h storage and SM of 1.8 has a capacity factor of 54.2%, an increase from 32.3% capacity factor with no storage, and an average annual energy efficiency of 20.6%. Calculations show a system with an output of 710 GWh e net electricity per year, 12 h storage, and SM of 2.4 to have an installed cost of $329 million, and an LCOE of 5.98 ¢/kWh e . This value meets the U.S. Department of Energy’s SunShot 2020 target of 6.0 ¢/kWh e ( U. S Department of Energy, 2012 ), but falls just shy of the 5.0 ¢/kWh e 2030 CSP target for dispatchable electricity ( U. S Department of Energy, 2017 ). The cost and performance results are minimally sensitive to most design parameters. However, a one-point change in the weighted annual cost of capital from 8 to 7% (better understood as a 12.5% change) translates directly to an 11% decrease (0.66 ¢/kWhe) in the LCOE.

Gorman, Brandon T.↗
DOE OSTI2023

Design of a High Flux Beam Characterization Device for Falling Particle Receivers

This paper outlines the design and error analysis for a flux characterization device (i.e. flux wand) which traverses the aperture of a falling particle receiver cavity providing the incident power measurement needed for the calculation of receiver efficiency without significantly disrupting receiver output. The design features a linear actuator, water cooled extension arm, and refractory bar. The refractory bar/flux wand is a diffusely reflective surface which reflects light as it is translated across the receiver aperture to provide a light intensity distribution that is correlated to a measured flux. The component sizing, constrained by a typical 30 frame per second camera and a 4-point average of the measured reflectance, is presented. Simulation reveals the error that results from a 5% variation in flux wand reflectance is within 4% of the true value.

Schroeder, Nathan↗
DOE OSTI2024

MRS Modelling in OpenFAST

Multi-rotor wind turbines, where more than one rotor is connected to a single support structure, are increasing in popularity due to their balance of power generation with component size, weight, and cost. Multi-rotor turbines are also common in marine energy, where deployment sites tend to be depth-constrained, limiting the maximum size of a rotor. To support the industry and research communities in designing and modeling multi-rotor turbines, the open-source turbine modeling tool OpenFAST, developed and supported by the National Renewable Energy Laboratory, is being extended to model multi-rotor wind and marine turbines. This presentation gives an overview of the current state of OpenFAST, planned changes to enable coupled aero-hydro-servo-elastic dynamic modeling of multi-rotor turbines, and examples of the types of turbines that OpenFAST will support.

marine energy↗
DOE OSTI2024

Optimization of R290 variable geometry heat exchangers

Air-to-refrigerant heat exchangers (HX) are vital components in Heating, Ventilating and Air Conditioning and Refrigeration (HVAC&R) equipment. Recent literature has proposed utilizing shape-optimized, non-round tubes to reduce component size and refrigerant charge, thus enabling the adoption of low-GWP natural refrigerants like R290. However, most designs are restricted to fixed tube configurations, limiting the overall performance potential. In this work, multi-objective optimization is used in a staged approach to develop variable geometry multi-pass air-to-R290 HXs with minimal volume and airside pressure drop. Non-round tubes are used throughout the domain and each pass may have different tube arrangements to maximize HX performance. Compared to conventional fin-tube HXs, the optimized designs demonstrate more than 60% reductions in envelope volume, 30% reductions in face area, and up to 24% reduction in airside pressure drop. Additionally, the refrigerant charge reduction was up to 64%, thus enabling safe use of flammable and mildly-flammable refrigerants.

42 ENGINEERING↗
DOE OSTI2024

Disentangling Sources of Momentum Fluctuations in Xe+Xe and Pb+Pb Collisions with the ATLAS Detector

High-energy nuclear collisions create a quark-gluon plasma, whose initial condition and subsequent expansion vary from event to event, impacting the distribution of the eventwise average transverse momentum [𝑃⁡([𝑝 T ])]. Disentangling the contributions from fluctuations in the nuclear overlap size (geometrical component) and other sources at a fixed size (intrinsic component) remains a challenge. This problem is addressed by measuring the mean, variance, and skewness of 𝑃⁡([𝑝 T ]) in 208 Pb + 208 Pb and 129 Xe + 129 Xe collisions at $\sqrt{S{NN}}$ = 5.02 and 5.44 TeV, respectively, using the ATLAS detector at the LHC. All observables show distinct features in ultracentral collisions, which are explained by a suppression of the geometrical component as the overlap area reaches its maximum. These results demonstrate a new technique to separate geometrical and intrinsic fluctuations, providing constraints on initial conditions and properties of the quark-gluon plasma, such as the speed of sound.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Refueling Infrastructure Scoping and Feasibility Assessment for Hydrogen Rail Applications

The feasibility and component cost of hydrogen rail refueling infrastructure is examined. Example reference stations can inform future studies on components and systems specifically for hydrogen rail refueling facilities. All of the 5 designs considered assumed the bulk storage of liquid hydrogen on-site, from which either gaseous or liquid hydrogen would be dispensed. The first design was estimated to refuel 10 multiple unit trains per day, each train containing 260 kg of gaseous hydrogen at 350 bar on-board. The second base design targeted the refueling of 50 passenger locomotives, each with 400 kg of gaseous hydrogen on-board at 350 bar. Variations from this basic design were made to consider the effect of two different filling times, two different hydrogen compression methods, and two different station design approaches. For each design variation, components were sized, approximate costs were estimated for major components, and physical layouts were created. For both gaseous hydrogen-dispensing base designs, the design of direct-fill using a cryopump design was the lowest cost due to the high cost of the cascade storage system and gas compressor. The last three base designs all assumed that liquid hydrogen was dispensed into tender cars for freight locomotives that required 7,500 kg of liquid hydrogen, and the three different designs assumed that 5, 50, or 200 tender cars were refueled every day. The total component costs are very different for each design, because each design has a very different dispensing capacity. The total component cost for these three designs are driven by the cost of the liquid hydrogen tank; additionally, delivering that much liquid hydrogen to the refueling facility may not be practical. Many of the designs needed the use of multiple evaporators, compressors, and cryopumps operating in parallel to meet required flow rates. In the future, the components identified here can be improved and scaled-up to better fit the needs of heavy-duty refueling facilities. This study provides basic feasibility and first-order design guidance for hydrogen refueling facilities serving emerging rail applications.

08 HYDROGEN↗
DOE OSTI2026

SAP-X2C: Optimally-Simple Two-Component Relativistic Hamiltonian with Size-Intensive Picture Change

We present a simple relativistic exact 2-component (X2C) Hamiltonian that models two-electron picture-change effects using Lehtola’s superposition of atomic potentials (SAP) [S. Lehtola, J. Chem. Theory Comput. 15, 1593−1604 (2019)]. The SAP-X2C approach retains the low cost and technical simplicity of the popular 1-electron X2C (1eX2C) predecessor but is significantly more accurate and has a well-defined thermodynamic limit, making it applicable to extended systems (such as large molecules and periodic crystals). The assessment of the SAP-X2C-based Hartree−Fock total and spinor energies, spin−orbit splittings, equilibrium bond distances, and harmonic vibrational frequencies suggests that SAP-X2C is similar to the more complex atomic meanfield (AMF) X2C counterparts in its ability to approximate the 4-component Dirac−Hartree−Fock reference.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Three and Two Phase Rotating Field Inductive Couplers for Wireless Power Transfer with One Phase per Layer Windings

Multiphase inductive wireless charging coils have been proposed recently to improve coupler surface power density, reduce component stress and size, and provide near-constant power delivery to charge mobile electric systems. Several aspects for the fundamental characterization of multiphase coils are explored up to six phases including approximate mutual inductance with size and turn variation, induced voltage, and output power estimation. The relative component stress and size of passive components for resonant operation are compared between the multiphase variants. A combination of an experimentally validated 3D electromagnetic finite element analysis (FEA) and power electronic co-simulations are used to validate the estimated quantities approximated with a mixture of analytical equations and an artificial neural network model for mutual inductance. A novel three-phase transmitter, two-phase receiver coil pair is also proposed for electric vehicle charging to reduce the number of connections and compensation complexity on the vehicle-side with improved power output compared to a two-phase configuration.

Lewis, Donovin D. [University of Kentucky]↗
DOE OSTI2024

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗
DOE OSTI2022

Influence of Cryomilling on Crystallite Size of Aluminum Powder and Spark Plasma Sintered Component

The present investigation aims to develop nanocrystalline (NC) pure aluminum powders using cryomilling technique and manufacture bulk components using spark plasma sintering (SPS). The cryomilling was performed on pure Al powders for 2, 6, and 8 h. The cryomilled powders were then consolidated using SPS to produce bulk components. The particle morphology and crystallite size of the powders and the bulk SPS components were analyzed using scanning electron microscopy (SEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results showed that the crystallite size of pure Al powders decreases with increased cryomilling time. The results also showed that the SPS at elevated temperatures resulted in a slight increase in crystallite size, however, the changes were insignificant. The mechanical properties of the bulk components were determined using a Vickers microhardness tester. The hardness of the cryomilled SPS component was determined to be three times higher than that of the unmilled SPS component. The mechanism for the reduction in crystallite size with increasing cryomilling time is discussed. This fundamental study provides an insight into the development of bulk nanomaterials with superior mechanical properties for automotive, aerospace, marine, and nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Super‐Droplet Method to Simulate Lagrangian Microphysics of Nuclear Fallout in a Homogeneous Cloud

Abstract Nuclear detonations produce hazardous local and global particles or fallout. Predicting fallout size, chemical components, and location is necessary to inform officials and determine immediate guidance for the public. However, existing nuclear detonation fallout models prescribe the particle size distributions based on limited observations. In this work, we apply the super‐droplet method, which is a numerical modeling technique developed for cloud microphysics, to simulate size distributions of particles in a mushroom cloud formed post‐detonation of a nuclear device. We model fallout formation and evolution with homogeneous nucleation and condensation of a single species and a Monte Carlo coagulation algorithm. We verify the numerical methods representing coagulation and condensation processes against analytical test problems. Additionally, we explore several scenarios for the integral system mass and yield in equivalent kilotons (kt) of TNT (trinitrotoluene). The fallout size distribution median diameter d pg follows a scaling law based on the integral system mass m v 0 kg and yield Y kt: nm. We test the effect of cloud turbulence, enhanced nucleation and growth, and vapor volatility with a sensitivity study. The range in median diameter predictions for simulations of historical tests performed over the Pacific encompass the measurements of particles sampled from the cloud caps. Predicted median particle size ranges up to 217, 123, 86, and 35 nm for historical tests with yields of 0.2, 0.7, 2, and 10 Mt, respectively. This work can be expanded in many different directions to build a more predictive model for fallout formation.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗