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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Optimization of Plug Nozzles Using CFD Informed Design Space Querying

This paper presents an axisymmetric CFD approach based on Reynolds-averaged Navier-Stokes (RANS) calculations for the shape optimization of plug nozzle contours for both supersonic cruise and landing/takeoff (LTO) conditions. Three key external plug design parameters were defined as independent variables in the optimization scheme, while nozzle performance was evaluated using thrust coefficient (Cfg) and discharge coefficient (Cd) as the primary dependent variables. By varying these parameters, a wide range of axisymmetric conic section plug profiles can be achieved, simplifying the problem. The paper also discusses the supersonic plug nozzle optimization approach, design space seeding, meshing, and CFD simulations for the optimization process. The results demonstrate that the approach is effective in exploring the parameter space and reducing computational expenses, making it a viable option for optimizing nozzle plug contours. Using this optimization toolchain, the study yielded preliminary designs for LTO, cruise, and LTO-cruise balanced plug nozzles.

CFD↗
NASA NTRS1984

Optimum design of rotor blades for vibration reduction in forward flight

Modern structural optimization techniques are applied to vibration reduction of helicopter rotor blades in forward flight. The objective function minimized consists of the oscillatory vertical hub shears or the hub rolling moments at one particular advance ratio. The behavior constraints are the frequency placements of the blade and the requirement that aeroelastic stability margins, in hover, remain unaffected by the optimization process. The aeroelastic stability and response analysis is based on a fully coupled flap-lag-torsional analysis of the blade. Numerical results are presented for some typical soft-in-plane hingeless rotor configurations indicating a 15-40 percent reduction in vibration levels, as well as a blade which is 20 percent lighter than the initial design. These results imply that structural optimization techniques can yield substantial practical benefits in the design process of rotor systems.

Friedmann, P. P.↗
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↗
NASA NTRS1991

Transient thermoelasticity and other body force effects in boundary element shape sensitivity analysis

Structural shape design sensitivity analysis (DSA) is presented for objects subjected to gravity, centrifugal, and general thermal loading. DSA employs implicit differentiation of the governing boundary integral equations. Both a surface integral and a particular integral approach are discussed for computation of these effects in response analysis and sensitivity analysis. It is shown that the particular integral approach is capable of computing the sensitivities of objects subjected to nonharmonic temperature distributions. Attention is also given to several techniques for the modeling of temperature distributions in the DSA process. In particular, an approach that eliminates the need for the incorporation of thermal response analysis and sensitivity analysis is described in the overall shape optimization process. A sharp corner formulation is also presented that can account for the jump in the surface traction components at a sharp corner in an interzone boundary.

Kane, James H.↗
NASA NTRS1993

ASRM propellant and igniter propellant development and process scale-up

A program of formulation and process development for ANB-3652 motor propellant was conducted to validate design concepts and screen critical propellant composition and process parameters. Design experiments resulted in the selection of a less active grade of ferric oxide to provide better burning rate control, the establishment of AP fluidization conditions that minimized the adverse effects of particle attrition, and the selection of a higher mix temperature to improve mechanical properties. It is shown that the propellant can be formulated with AP and aluminum powder from various producers. An extended duration pilot plant run demonstrated stable equipment operation and excellent reproducibility of propellant properties. A similar program of formulation and process optimization culminating in large batch scaleup was conducted for ANB-3672 igniter propellant. The results for both ANB-3652 and ANB 37672 confirmed that their processing characteristics are compatible with full-scale production.

Landers, L. C.↗
NASA NTRS1999

Skin Friction Drag Predictions: Summary of CFD Cross Checks, Wing/Body

The objective of the present study was to address the questions of: 1) how reliably or consistently the Navier-Stokes methods and processes used by the various organizations can predict integrated skin friction drag, and 2) how well the methods can predict trends within a family of optimized configurations. As a first step, all available skin friction drag predictions were accumulated to obtain a mean and standard deviation for the TCA (Technology Concept Airplane) baseline and each of the optimized configurations. It is observed that the optimization process has had little effect on the predicted skin friction drags. The variation in the mean that is observed is dwarfed by the standard deviations. In order to understand the reasons for the relatively large spreads in the computed results, a number of auxiliary computations have been performed using the UPS and OVERFLOW codes in an effort to identify and quantity potential sources of the variations.

Lawrence, Scott↗
DOE OSTI2024

Room-temperature fabrication of garnet-type solid-electrolyte: Optimizing particle size for high ionic conductivity

Dense and uniform Li 6.25 Al 0.25 La 3 Zr 2 O 12 (Al-doped LLZO) solid-electrolyte film of ~24 µm thickness is successfully fabricated by room temperature aerosol deposition (AD) method. The process optimization study revealed that careful control of particle size and morphology is one of critical determinants in the development of a compact AD membrane. Notably, our method facilitated an impressive ionic conductivity of approximately 10 –5 S cm –1 , bypassing the necessity for post-annealing processes, a milestone in itself. However, it is hypothesized that the attained conductivity is somewhat restrained by factors such as smaller grain size and potential surface degradation due to moisture exposure during fabrication, indicating avenues for further research. Looking forward, detailed investigations into the film's microstructure and its impact on transport properties will be a focal point, alongside potential enhancements through post-annealing and particle coating strategies. Finally, this research hints at a promising trajectory for the development of high-efficiency solid-state battery technology.

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

Advanced Modeling and Process-Materials Co-Optimization Strategies for Swing Adsorption Based Gas Separations

This project devised a computational framework for simultaneously co-optimizing pressure swing adsorption process designs along with the sorbent materials (specifically, metal-organic frameworks) to be employed in the associated packed bed columns. The materials optimization aspect involved search over a design space that can describe the material’s molecular structure, while the process optimization aspect considered various process degrees of freedom for steps arising in various cycle configurations. This framework was demonstrated on the separation of nitrogen and carbon dioxide, which arises ubiquitously in a multitude of post-combustion carbon capture and “blue” hydrogen production applications. Our results led to metal-organic framework molecular descriptor choices that are predicted to outperform standard structures used in practice, providing guidance for future metal-organic framework synthesis efforts.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

High Throughput Source-less Plasma Deposition of Structured Silicon Anodes for Lithium-Ion Batteries

Amprius developed a manufacturing solution for silicon nanowire anode that relies on an inexpensive, high throughput, and high gas precursor utilization plasma deposition method that uses the anode foils as electrodes for plasma generation. The capacitively couple plasma (CCP) method is used in semiconductor and photovoltaic industry and Amprius modified existing high throughput equipment to use anode foils and to deposit amorphous silicon. The equipment was installed ahead of the program at Amprius site. The rest of the tasks included foil handling and process development. The equipment passed site acceptance tests (SAT) and the process parameter mapping was completed, indicating that the target process window limits produce output materials at the rate and with yield and specifications that meet the manufacturing target criteria. Amprius has hired supporting personnel to optimize processes and run the equipment. A parallel task verified the baseline performance of the silicon anode material, to be used as reference for the new manufacturing method.

25 ENERGY STORAGE↗
DOE OSTI2023

Laser Welded Burst Disk Weld Tooling

A production run of 5550 hermetically sealed cylinder assemblies with precision pressure relief burst discs will be assembled and laser welded at a manufacturing lab at Sandia National Labs. Production of these cylinder assemblies requires many steps, including piece part machining, geometric inspection, cleaning, subassembly, complete assembly via laser welding, and finally leak checking. While this production run is large enough to invest in process optimization and specialized tooling, it is not quite large enough to dedicate new lab space and specify equipment specifically for this job. This study will investigate process parameters and their effects on quality and process flow time, as well as a fixturing design study with the goal of reducing process time while maintaining quality requirements.

42 ENGINEERING↗
DOE OSTI2022

U-gas +Cool GTL™ - A New Integrated Process for Direct Biomass Conversion to Liquid Fuels

The U-Gas gasification technology, marketed by Sungas, is a proven fluid bed gasification technology for biomass conversion. U-Gas has been tested on a wide variety of biomass feeds including wood and waste streams. The U-Gas Technology has successfully converted wood for more than 20 years in a gasification plant in Skive Denmark at the 150t/d size. GTI has also recently developed the Cool GTL process for converting biogas to high quality gasoline, jet, and diesel fuels. The technoeconomics and LCA for the combination of the two technologies results an integrated optimized process, which will be discussed. The Cool GTL process is still in development and the development should be complete by 2023. Cool GTL converts high CO2 content feeds to synthesis gas with a 2-2.4/1 H2/CO ratio suitable for fuels synthesis. The process is based on a novel, highly stabile CO2/steam reforming catalyst. The 2.0-2.4/1 H2/CO synthesis gas ratio is always achieved, independently of feed CO2 content, by adjusting the amount of water added according to the amount of CO2 in the feed. The reformer catalyst has been tested for 500 hours and shows no measurable deactivation. The product from the reformer then goes directly to a low temperature slurry bed Fischer Tropsch reactor with an integrated finishing hydroisomerization reactor which makes hydrocarbon liquids from the synthesis gas. With this configuration no wax is produced. The technoeconomics and carbon intensity for the integration of UGas and the Cool GTL processes will be compared to other biomass conversion approaches. The use of electrolysis to boost H2 in the feed and increase liquid production will also be analyzed as a potential process improvement with sensitivities to the cost of electricity and the use of renewable electricity.

09 BIOMASS FUELS↗
DOE OSTI2024

Microstructural and Hall–Petch Analysis of Additively Manufactured Ferritic Alloy Using 2507 Duplex Stainless Steel Powder

The powder bed fusion–laser beam (PBF-LB) process, a method of additive manufacturing (AM), was used to print duplex stainless steel (DSS) using commercial-grade 2507 powders. While conventionally processed DSS has a two-phase microstructure consisting of 50% austenite and 50% ferrite, the PBF-LB-printed 2507 alloy was nearly 100% ferrite. Optimal processing conditions that minimized porosity were determined to be 290 W laser power and 1000 mm/s scan speed, and grain size, texture, and phases were characterized as a function of laser power and scan speed. Grain size increased with increasing laser power but decreased with increasing scan speed. A <100> texture diminished with increasing scan speed from 1000 mm/s to 1400 mm/s. No austenite phase was detected. Transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) characterization revealed nanoscale chromium nitride precipitates in the ferritic matrix (incoherent hexagonal close-packed (HCP) precipitates at grain boundaries and coherent body-centered cubic (BCC) precipitates within the grains) and a high density of tangled dislocations. Tensile tests of as-printed alloys showed a yield strength of 570 MPa, an ultimate tensile strength of 756 MPa, and an elongation to failure of 10%. The tensile properties were analyzed based on the observed microstructure considering grain size, nanoscale precipitates, and the high density of dislocations.

Crystallography↗
NASA NTRS1976

Numerical Airfoil Optimization Using a Reduced Number of Design Coordinates

A method is presented for numerical airfoil optimization whereby a reduced number of design coordinates are used to define the airfoil shape. The approach is to define the airfoil as a linear combination of shapes. These basic shapes may be analytically or numerically defined, allowing the designer to use his insight to propose candidate designs. The design problem becomes one of determining the participation of each such function in defining the optimum airfoil. Examples are presented for two-dimensional airfoil design and are compared with previous results based on a polynomial representation of the airfoil shape. Four existing NACA airfoils are used as basic shapes. Solutions equivalent to previous results are achieved with a factor of more than 3 improvements in efficiency, while superior designs are demonstrated with an efficiency greater than 2 over previous methods. With this shape definition, the optimization process is shown to exploit the simplifying assumptions in the inviscid aerodynamic analysis used here, thus demonstrating the need to use more advanced aerodynamics for airfoil optimization.

Vanderplaats, G. N.↗
NASA NTRS2012

HURON (HUman and Robotic Optimization Network) Multi-Agent Temporal Activity Planner/Scheduler

HURON solves the problem of how to optimize a plan and schedule for assigning multiple agents to a temporal sequence of actions (e.g., science tasks). Developed as a generic planning and scheduling tool, HURON has been used to optimize space mission surface operations. The tool has also been used to analyze lunar architectures for a variety of surface operational scenarios in order to maximize return on investment and productivity. These scenarios include numerous science activities performed by a diverse set of agents: humans, teleoperated rovers, and autonomous rovers. Once given a set of agents, activities, resources, resource constraints, temporal constraints, and de pendencies, HURON computes an optimal schedule that meets a specified goal (e.g., maximum productivity or minimum time), subject to the constraints. HURON performs planning and scheduling optimization as a graph search in state-space with forward progression. Each node in the graph contains a state instance. Starting with the initial node, a graph is automatically constructed with new successive nodes of each new state to explore. The optimization uses a set of pre-conditions and post-conditions to create the children states. The Python language was adopted to not only enable more agile development, but to also allow the domain experts to easily define their optimization models. A graphical user interface was also developed to facilitate real-time search information feedback and interaction by the operator in the search optimization process. The HURON package has many potential uses in the fields of Operations Research and Management Science where this technology applies to many commercial domains requiring optimization to reduce costs. For example, optimizing a fleet of transportation truck routes, aircraft flight scheduling, and other route-planning scenarios involving multiple agent task optimization would all benefit by using HURON.

Hua, Hook↗
NASA NTRS2018

Second-Generation Design of Micro-Spec: A Medium-Resolution, Submillimeter-Wavelength Spectrometer-on-a-Chip

Micro-Spec (μ-Spec) is a direct-detection spectrometer which integrates all the components of a diffraction-grating spectrometer onto a ∼10-cm2 chip through the use of superconducting microstrip transmission lines on a single-crystal silicon substrate. A second-generation μ-Spec is being designed to operate with a spectral resolution of 512 in the submillimeter (500-1000 μm, 300-600 GHz) wavelength range, a band of interest for several spectroscopic applications in astrophysics. High altitude balloon missions would provide the first test bed to demonstrate the μ-Spec technology in a space-like environment and would be an economically viable venue for multiple observation campaigns. This work reports on the current status of the instrument design and will provide a brief overview of each instrument subsystem. Particular emphasis will be given to the design of the spectrometer's two-dimensional diffractive region, through which the light of different wavelengths is focused on the detectors along the focal plane. An optimization process is employed to generate geometrical configurations of the diffractive region that satisfy specific requirements on spectrometer size, operating spectral range, and performance. An optical design optimized for balloon missions will be presented in terms of geometric layout, spectral purity, and efficiency.

Cataldo, G.↗
DOE OSTI2021

Melt Pool and Heat Treatment Optimization for the Fabrication of High-Strength and High-Toughness Additively Manufactured 4340 Steel

Additively manufactured (AM) components offer superior design flexibility compared to their conventionally manufactured counterparts, and optimizing processing parameters is key to achieving high-quality depositions with desirable and predictable mechanical properties. This study was focused on 4340 steel fabricated using laser powder bed fusion (LPBF), and 42 laser power and scan speed combinations have been systematically investigated to determine an optimized melt pool geometry that would ensure fully-dense parts. The AM material was compared with a wrought 4340 equivalent and studied in two customized heat treated conditions, optimized for strength and toughness, respectively. The microstructures of the as-fabricated and heat treated AM and wrought materials were characterized to assess differences introduced by the layer-by-layer fabrication process and subsequent heat treatment. Tensile properties of both materials were also evaluated and demonstrate that the AM materials offer equal or superior properties compared to the wrought equivalents. Differences in fracture surface morphologies indicate the distinct failure mechanisms associated with the materials’ characteristic microstructures, and the role of inclusions in the failures was studied to elucidate these differences. Complementary to the experimental investigations, the dataset was leveraged to make recommendations for future design of experiments to optimize AM build parameters in other material systems. A statistical Monte Carlo analysis was used to predict the interpolation error produced using reduced datasets and to enable informed processing parameters selection. These findings are discussed to make recommendations for the use of AM materials for high-integrity structural applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 μm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Pitfalls in parameters: practical process development in chemical vapor processing of SiC

Vapor processing of high-value materials, such as silicon carbide (SiC), is of interest for many industries, including aerospace and energy production. Chemical vapor infiltration (CVI) of additively manufactured components is an especially attractive manufacturing process currently in development. Here, a novel development workflow is demonstrated with the H 2 –CH 3 SiCl 3 gas system for SiC to accelerate the process optimization of CVI SiC. A combination of calculated thermodynamics and high-throughput experimental chemical vapor deposition (CVD) coatings substantially reduced the experiments required with slow CVI processes. The computational results accurately predicted changes in the thermodynamic conditions tested, while CVD coatings – characterized by Raman spectroscopy – addressed changes in kinetic parameters. This workflow is also applicable to other vapor-processing systems, such as pyrolytic carbon, ZrC, or Si 3 N 4 .

Lamm, Benjamin W. [Oak Ridge National Laboratory (↗