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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Minimization of thermal deformation in crystal optics for high repetition-rate FEL

Minimizing thermal deformation in X-ray crystal optics is crucial for preserving coherence and wavefront in high-repetition-rate free-electron lasers (FELs). This study presents two approaches to reduce pulse-by-pulse transient thermal deformation in diamond crystals used in cavity-based X-ray FELs (CBXFELs): (1) cryogenic cooling with liquid nitrogen (LN₂), and (2) second-order correction via focusing optics. We revisit the temperature-dependent thermal-mechanical properties of diamond and silicon, implement a finite-element analysis (FEA) method to accelerate convergence to a quasisteady-state regime. Results show that LN₂-cooled diamond crystals meet the stringent deformation requirement of less than 15 pm RMS for the pulse at mJ scale at 1 MHz repetition frequency, and up to 1.5 mJ for 100 kHz. Second-order correction by using focusing elements within the cavity can reduce the impact of thermal deformation for both liquid nitrogen and water cooling.

free electron laser↗
DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than non-detonating engines. To understand the high-speed heat transfer dynamics inside an RDE, a novel, high-frequency heat flux gage is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Sensor bench testing is performed using a hot plate as a heat source, and the sensor response is compared to a finite-element analysis (FEA) model. The sensor response is then tested inside a water-cooled RDE and the wall heat flux is compared to calorimetry data.

rotating detonation engines↗
DOE OSTI2025

Restructuring and Optimizing Reactor Building Lifting Processes & Designing a Solution for an Overhead Door Handling Forklift Attachment

This poster presents two innovative projects aimed at enhancing operational efficiency and safety at the Advanced Test Reactor (ATR) Complex. The first project focuses on restructuring the existing lift book used for hoisting operations within the ATR Reactor Building. The current lift book, a cumbersome 150+ page document, is being transformed into a more efficient format using charts that allow for quick identification of maximum lift heights based on object footprint and weight. This new method also considers various parameters such as floor integrity and reactor status, dividing entries into four distinct charts to improve usability and safety during lifts. The second project involves designing a specialized forklift attachment for handling an overhead door at the ATR Reactor Building. The attachment is engineered to securely lift and lower a 1200lb, 14ft long door, ensuring safe replacement operations. The design process included research on forklift attachment codes, modeling in Autodesk Inventor, and testing through Finite Element Analysis (FEA) and hand calculations to confirm the attachment's structural integrity. Future work includes completing detailed drawings and an Engineering Calculations Analysis and Review (ECAR) document to proceed with manufacturing and assembly. Together, these projects demonstrate a commitment to optimizing reactor building operations through innovative engineering solutions and safety considerations.

42 - ENGINEERING↗
DOE OSTI2025

HotCell Components

To support operations in the HFEF Hot Cell and the FCF Hot Cell, multiple components were designed to support the Bottle Cutter Project and the Sodium Loop Project. These components were designed and analyzed to ensure they can function in their environment and be operated remotely. FEA analysis were performed, prototypes were made, and parts were manufactured to complete this project. This poster documents these parts and test results.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Innovative accident tolerant fuel concept enabled through direct manufacturing technology

Nuclear energy is one of the largest sources of carbon-free electricity in the world. Some countries are looking at new ways to support and revitalize the nuclear sector since the Fukushima disaster. The accident tolerant fuel program is geared toward improving the safety of nuclear energy by investigating materials that can replace or modify the current uranium-dioxide nuclear fuel and zirconium-based cladding. This research program is being supported by all major nuclear countries since 2011. The practical limitations on allowable uranium enrichment has taken the focus away from the most promising fuels with high radioactivity retention such as tristructural isotropic particle fuel. To overcome such enrichment limitation, a new fuel concept is proposed using advanced ceramic direct manufacturing with laser-induced chemical vapor deposition. The fuel-as-fiber concept is an accident-tolerant fuel design that features high thermal conductivity, strong capability of radioactivity retention and most importantly requires reasonable enrichment levels with uranium nitride as the fuel. In this work, the initial fabrication of uranium-based fuel with laser-induced chemical vapor deposition technology is demonstrated. Then an advanced multi-physics guided modeling approach based on finite element analysis codes and informed by the manufacturing capabilities is developed to accelerate the advancement of fuel-as-fiber concept for use in current light-water reactor technology. The detailed thermomechanical analysis showed promising results for viability of the innovative fuel-as-fiber concept. The predicted stresses in the fuel structural materials were similar to the case of tristructural isotropic particle fuel experience base that has shown excellent reliability in retention of fuel radioactivity at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

U-splines: Splines over unstructured meshes

U-splines are a novel approach to the construction of a spline basis for representing smooth objects in Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE). A spline is a piecewise-defined function that satisfies continuity constraints between adjacent cells in a mesh. U-splines differ from existing spline constructions, such as Non-Uniform Rational B-splines (NURBS), subdivision surfaces, T-splines, and hierarchical B-splines, in that they can accommodate local variation in cell size, polynomial degree, and smoothness simultaneously over more varied mesh configurations. Mixed cell types (e.g., triangle and quadrilateral cells in the same mesh) and T-junctions are also supported, although the continuity of interfaces with triangle and tetrahedral cells is limited in the present work. The U-spline algorithm introduces a new technique for using local null space solutions to construct basis functions for the global spline null space problem. The U-spline construction is presented for curves, surfaces, and volumes with higher dimensional generalizations possible. Lastly, a set of requirements are given to ensure that the U-spline basis is positive, forms a partition of unity, is complete, and is locally linearly independent.

42 ENGINEERING↗
DOE OSTI2024

High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An extrapolation method to remove spurious stress concentration in micromechanical analyses of composites using pixel-based meshes

It is easier to generate a finite element mesh of complicated geometries with voxel-based meshes compared to conformal meshes. However, the local stresses in voxel-based meshes are higher owing to artificial stress concentration caused due to jagged lines that approximate a curve. Here, we propose a method that accounts for this anomaly which would lead to accurate prediction of maximum von Mises stress in voxel-based meshes. The method is based on the variation of reciprocal of stresses and associated numerical gradient. The prediction of the proposed method is compared against the results of a conformal mesh by considering four two-dimensional example problems. The accuracy of the proposed method is verified using different mesh densities, material properties, and integration schemes. The proposed method was also implemented on a conformal mesh to verify that it filters out just the spurious stress concentration and not the realistic stress concentration.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancing EnergyPlus capabilities to model dynamic building envelopes using python plugin

Nearly half of the energy consumption in the United States is related to buildings, resulting in an urgent need to develop innovative technologies to improve building energy efficiency. Dynamic building envelopes, comprising switchable insulation and thermal energy storage materials, have been proposed recently as a promising solution to reduce buildings' heating and cooling loads by thermally coupling the indoor environment with the ambient environment when beneficial while decoupling them when outdoor conditions are not favorable. Although various related technologies are still underway, the whole-building energy modeling tools, like EnergyPlus, do not have the capability to simulate the transient and dynamic nature of dynamic envelope materials and components to accurately predict their impact on building energy use. The objective of this study is to formulate a method in EnergyPlus simulation engine to model multilayer envelopes, comprising dynamic building materials with variable thermophysical properties, and discuss the changes made to the program using a Python plugin. Furthermore, the thermal performance of the dynamic envelopes using the proposed method is compared and verified with the results from a well-established commercial code, COMSOL Multiphysics. A parametric assessment is also conducted to evaluate the energy efficiency benefits of dynamic envelopes in a single-family residential building, demonstrating total annual energy savings up to 11.6 %, when a dynamic envelope operates alone, and up to 18.2 % when it is combined with a thin layer of phase change material as a thermal storage medium. Finally, a United States wide energy efficiency assessment is presented to showcase the geographical spread of the energy savings. The method designed and implemented in this study provides the researchers with the ability to implement their dynamic insulation methods in EnergyPlus and evaluate the whole building energy impact.

25 ENERGY STORAGE↗
DOE OSTI2023

Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

Conventional sheet metal forming tooling in the automotive industry is made up of hardened steel and used for mass-production. Prototype tooling made of metal is durable, but it is only used for a small number of parts despite its high cost, contributing heavily to the vehicle development cost. Additive Manufacturing (AM) offers a low-cost alternative for fabricating tooling suitable for low-volume production. Here, this study investigates the feasibility of using AM polymer composite tooling for the stamping of 1.5mm thickness HSS 590 steel sheets through a two-pronged approach – experimental and numerical analysis. Sheet metal stamping experiments were conducted with glass fiber reinforced polycarbonate (GF-PC) AM polymer tooling and their performance was evaluated based on various metrics such as tool deformation and part accuracy. Finite element simulations of the stamping process were performed, which accurately captured the tool deformations seen in experiments with the use of anisotropic material models. The effective use of simulations in optimizing process parameters to achieve the desired final part geometry is also demonstrated. The GF-PC AM polymer composite tooling was found to be well suited for low volume production applications with potential cost savings.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Machine learning based inverse modeling of full-field strain distribution for mechanical characterization of a linear elastic and heterogeneous membrane

Heterogeneous membranes or films are thin and soft structures with spatial variations in material property and thickness. Mechanical behavior of heterogeneous membranes is not well understood, mainly due to the difficulty in obtaining accurate and reliable material property data. To understand the mechanical behavior of these materials, accurate and efficient characterization methods for heterogeneous membranes are needed. Here, in this paper, an inverse method based on machine learning is developed to efficiently extract mechanical properties from full-field strain distributions. This approach is demonstrated on a flat heterogeneous membrane with uniform thickness formed by up to four linear elastic synthetic materials in a grid arrangement, and deforming in a moderate strain range (true strain ~10%). The results show that the machine learning method achieves accuracy comparable to the traditional inverse finite element method, and is 6 orders of magnitude faster in the demonstrated case studies.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Regiospecific Cellulose Orientation and Anisotropic Mechanical Property in Plant Cell Walls

Cellulose microfibrils (CMFs) are a major load-bearing component in plant cell walls. Thus, their structures have been studied extensively with spectroscopic and microscopic characterization methods; but the findings from these two approaches were inconsistent, which hampers mechanistic understanding of cell wall mechanics. Here, we report the regiospecific assembly of CMFs in the periclinal wall of plant epidermal cells. Using sum frequency generation spectroscopic imaging, we found that CMFs are highly aligned in the cell edge region where two cells form a junction, whereas they are mostly isotropic on average throughout the wall thickness in the flat face region of the epidermal cell. This subcellular-level heterogeneity in CMF alignment provided insights into tissue-level anisotropy in tensile modulus of cell wall materials. Furthermore, this finding also has resolved a previous contradiction between the spectroscopic and microscopic imaging studies, which paves a foundation for better understanding of cell wall artichecture, especially structure-geometry relationships.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

First test results of the HGCAL concentrator ASICs: ECON-T and ECON-D

With over 6 million channels, the High Granularity Calorimeter for the CMS HL-LHC upgrade presents a unique data transmission challenge. The ECON ASICs provide a critical stage of on-detector data compression and selection for the trigger path (ECON-T) and data acquisition path (ECON-D) of the HGCAL. The ASICs, fabricated in 65 nm CMOS, are radiation tolerant up to 200 Mrad and require low power consumption: < 2.5 mW/sensor-channel per chip. Here, we report on the first functionality and radiation tests for the ECON-D-P1 full-functionality prototype. We present a comparison of single event effect (SEE) cross sections measured for different methods of triple modular redundancy using test results from the ECON-T-P1 full-functionality prototype.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗
DOE OSTI2020

Utah FORGE: Phase 3 Magnetotelluric (MT) Data

New high-quality tensor MT data at 122 sites, including the vertical magnetic field and utilizing ultra-remote referencing, have been acquired over the Utah FORGE project area. The results will be used to delineate the densities of faults and fractures in crystalline basement rocks, to define the heat sources, and to derive baseline 3D resistivity structure for later MT monitoring of temporal changes in resistivity structure following well stimulation in the EGS reservoir. There are three files here related to Utah FORGE magnetotelluric (MT) data acquisition and processing. The FORGE MT EDIs zip file contains the observed MT responses in industry-standard EDI format. For each site, there is an EDI response file that utilized a local independent reference for noise cancellation, and a file that utilized a distant reference cancelling noise associated with the DC transmission line of the Delta IPP passing down the west side of Milford Valley. These two site files could be merged as appropriate. The FORGE Model Cell Center file contains the model volume of the 3D Forge MT inversion for characterizing the resistivity structure in the project area. It was derived using finite element inversion methodology described in Wannamaker et al, in the attached FORGE Phase3 Geophysics paper, from the MT observation EDI files. It is ASCII format (.dat) and entries are defined at top of the file in a simple x-y-z-Rho listing in UTM coordinates. The element layers drape the topography so the Rho value layers are not purely horizontal slices. This greatly simplifies the listing.

15 GEOTHERMAL ENERGY↗