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DOE OSTI2022

Experimental Studies and Energy Modeling for Evaluating Performance of Various Deep Wall Retrofits

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory, and the University of Minnesota conducted a three-year, multipart study on residential retrofit wall assemblies. The project, which was funded by the U.S. Department of Energy’s Building Technology Office, aimed to compare a range of residential wall retrofit systems that prioritized affordability, durability, and energy savings potential. The research team identified, constructed, tested, simulated, and analyzed the feasibility and economics of 16 wall retrofit assemblies (14 test configurations and two baseline configurations) that can be applied to the exterior side of existing walls (either with or without the existing cladding). The 16 wall assemblies were installed in an in-situ laboratory environment, to evaluate the ease of construction and study the thermal and hygrothermal performance of the walls. This paper presents the methodology used to evaluate the thermal performance of the walls and discusses the energy modeling results of the study. The results from the experiments were used to calibrate a THERM model of each wall assembly, which was then applied to a whole building using the EnergyPlus 8.6 simulation engine. A residential prototype building was used to extrapolate whole-building energy savings in each U.S. climate zone. To capture the conditions of the largest number of homes in the United States, the most frequent building characteristics (e.g., attic insulation level, window specifications, foundation insulation, etc.) were extracted from ResStock data and applied to the prototype model. Results from the energy modeling showed that the climate zones with the highest potential for retrofit savings are those which are heating-dominated (i.e., Cold and Very Cold climate designations). In these climate zones, heating and cooling energy savings due to the wall retrofits alone ranged from 21.5% to 38.2%.

Nagda, Harshil↗

DOE OSTI2024

Robust training of machine learning interatomic potentials with dimensionality reduction and stratified sampling

Abstract Machine learning interatomic potentials (MLIPs) enable accurate simulations of materials at scales beyond that accessible by ab initio methods and play an increasingly important role in the study and design of materials. However, MLIPs are only as accurate and robust as the data on which they are trained. Here, we present DImensionality-Reduced Encoded Clusters with sTratified (DIRECT) sampling as an approach to select a robust training set of structures from a large and complex configuration space. By applying DIRECT sampling on the Materials Project relaxation trajectories dataset with over one million structures and 89 elements, we develop an improved materials 3-body graph network (M3GNet) universal potential that extrapolates more reliably to unseen structures. We further show that molecular dynamics (MD) simulations with the M3GNet universal potential can be used instead of expensive ab initio MD to rapidly create a large configuration space for target systems. We combined this scheme with DIRECT sampling to develop a reliable moment tensor potential for titanium hydrides without the need for iterative augmentation of training structures. This work paves the way for robust high-throughput development of MLIPs across any compositional complexity.

Qi, Ji (ORCID:0000000158089931)↗

NASA NTRS2006

Preliminary Trade Study of Phase Change Heat Sinks

For short durations, phase change based heat rejection systems are a very effective way of removing heat from spacecraft. Future NASA vehicles, such as the Crew Exploration Vehicle (CEV), will require non-radiative heat rejection systems during at least a portion of the planned mission, just as their predecessors have. While existing technologies are available to modify, such as Apollo era sublimators, or the Space Shuttle Flash Evaporator System (FES), several new technologies are under development or investigation to progress beyond these existing heat rejection systems. Examples include the Multi-Fluid Evaporator developed by Hamilton Sundstrand, improvements upon the Contaminant Insensitive Sublimator originally developed for the X-38 program, and a Compact Flash Evaporator System (CFES). Other possibilities evaluate new ways of operating existing designs. The new developments are targeted at increasing operating life, expanding the environments in which the system can operate, improving the mass and volume characteristics, or some combination of these or other improvements. This paper captures the process and results of a preliminary trade study performed at Johnson Space Center to compare the various existing and proposed phase change based heat rejection systems for the CEV. Because the new systems are still in development, and the information on existing systems is extrapolation, this trade study is not meant to suggest a final decision for future vehicles. The results of this early trade study are targeted to aid the development efforts for the new technologies by identifying issues that could reduce the chances of selection for the CEV.

Anderson, Molly↗

NASA NTRS2019

Dynamic Testing of a High-Specific-Torque Concentric Magnetic Gear

This paper presents initial measurements of the efficiency of NASA's 2nd magnetic gear prototype. A detailed discussion of the test rig's design and capabilities was presented, along with a thorough uncertainty analysis. The reported uncertainties are 95% confidence intervals that include the effects of temperature and parasitic loads. The prototype's response was measured at output speeds between 124 rpm and 744 rpm for a controlled output torque of 10 Nm (8% of the prototype's maximum torque). After correcting for tare losses, the prototype's efficiency was found to decrease from 90.0% to 83.0% as speed increased. If the efficiency is extrapolated to a typical operating condition (85% of maximum torque) using the good assumption that energy loss is approximately independent of the transmitted torque, the expected efficiency would be 99.0% to 98.4%, which exceeds the state of the art for these speeds.

magnetic gears↗

NASA NTRS2022

After DART: Using the first full-scale test of a kinetic impactor to inform a future planetary defense mission

NASA’s Double Asteroid Redirection Test (DART) is the first full-scale test of an asteroid deflection technology. Results from the hypervelocity kinetic impact and Earth-based observations, coupled with LICIACube and the later Hera mission, will result in measurement of the momentum transfer efficiency accurate to ~10% and characterization of the Didymos binary system. But DART is a single experiment; how could these results be used in a future planetary defense necessity involving a different asteroid? We examine what aspects of Dimorphos’s response to kinetic impact will be constrained by DART results; how these constraints will help refine knowledge of the physical properties of asteroidal materials and predictive power of impact simulations; what information about a potential Earth impactor could be acquired before a deflection effort; and how design of a deflection mission should be informed by this understanding. We generalize the momentum enhancement factor β, showing that a particular direction-specific β will be directly determined by the DART results, and that a related direction-specific β is a figure of merit for a kinetic impact mission. The DART β determination constrains the ejecta momentum vector, which, with hydrodynamic simulations, constrains the physical properties of Dimorphos’s near-surface. In a hypothetical planetary defense exigency, extrapolating these constraints to a newly discovered asteroid will require Earth-based observations and benefit from in-situ reconnaissance. We show representative predictions for momentum transfer based on different levels of reconnaissance and discuss strategic targeting to optimize the deflection and reduce the risk of a counterproductive deflection in the wrong direction.

Asteroids↗

DOE OSTI2020

Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems

A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.

41 EE - Solar Energy Technologies Office (EE-4S)↗

NASA NTRS1989

Simulation studies of improved sounding systems

Two instrument designs for indirect satellite sounding of the atmosphere in the infrared are represented by the High Resolution Infra-Red Sounder, Model 2 (HIRS-2) and by the Advanced Meteorological Temperature Sounder (AMTS). The relative capabilities of the two instruments were tested by simulating satellite measurements from a group of temperature soundings, allowing the two participants to retrieve the temperature profiles from the simulated data, and comparing the results with the original temperature profiles. Four data sets were produced from radiosondes data extrapolated to a suitable altitude, representing continents and oceans, between 30S and 30N. From the information available, temperature profiles were retrieved by two different methods, statistical regression and inversion of the radiative transfer equation. Results show the consequence of greater spectral purity, concomitant increase in the number of spectral intervals, and the better spatial resolution in partly clouded areas. At the same time, the limitation of the HIRS-2 without its companion instrument leads to some results which should be ignored in comparing the two instruments. A clear superiority of AMTS results is shown.

Yates, H.↗

DOE OSTI2024

Acceptance criteria for in situ surveillance of MSR materials based on thermally-loaded mechanical test articles

This report describes practices and acceptance test procedures for designing, running, and maintaining a material surveillance program in a future operating molten salt reactor. The programs described here rely on test data from passively actuated mechanical test articles inserted into critical regions of the reactor and periodically removed for out-of-reactor testing. The report defines definite acceptance procedures, based on the results of these tests, to determine whether a component can continue to operate accounting for the accumulation of environmentally-assisted mechanical damage in the component materials to date, and extrapolated out through the next inspection period. Additionally, the report describes work on a software tool implementing many of the surveillance methods and procedures described here and progress on simplified methods for inferring damage accumulation in the test articles, based on out-of-reactor thermal cycling, that do not rely on sophisticated numerical analysis.

36 MATERIALS SCIENCE↗

NASA NTRS2002

On the Choice of Variable for Atmospheric Moisture Analysis

The implications of using different control variables for the analysis of moisture observations in a global atmospheric data assimilation system are investigated. A moisture analysis based on either mixing ratio or specific humidity is prone to large extrapolation errors, due to the high variability in space and time of these parameters and to the difficulties in modeling their error covariances. Using the logarithm of specific humidity does not alleviate these problems, and has the further disadvantage that very dry background estimates cannot be effectively corrected by observations. Relative humidity is a better choice from a statistical point of view, because this field is spatially and temporally more coherent and error statistics are therefore easier to obtain. If, however, the analysis is designed to preserve relative humidity in the absence of moisture observations, then the analyzed specific humidity field depends entirely on analyzed temperature changes. If the model has a cool bias in the stratosphere this will lead to an unstable accumulation of excess moisture there. A pseudo-relative humidity can be defined by scaling the mixing ratio by the background saturation mixing ratio. A univariate pseudo-relative humidity analysis will preserve the specific humidity field in the absence of moisture observations. A pseudorelative humidity analysis is shown to be equivalent to a mixing ratio analysis with flow-dependent covariances. In the presence of multivariate (temperature-moisture) observations it produces analyzed relative humidity values that are nearly identical to those produced by a relative humidity analysis. Based on a time series analysis of radiosonde observed-minus-background differences it appears to be more justifiable to neglect specific humidity-temperature correlations (in a univariate pseudo-relative humidity analysis) than to neglect relative humidity-temperature correlations (in a univariate relative humidity analysis). A pseudo-relative humidity analysis is easily implemented in an existing moisture analysis system, by simply scaling observed-minus background moisture residuals prior to solving the analysis equation, and rescaling the analyzed increments afterward.

Dee, Dick P.↗

NASA NTRS1995

Influence of Geometry and Flow Variations on NO Formation in the Quick Mixer of a Staged Combustor

Staged combustion, such as Rich-Burn/Quick-Mix/Lean-Burn (RQL), is a viable strategy to meet nitric oxide (NO) emission goals for both stationary and propulsion gas turbine engines. A critical element of the design is the quick mixer section where the potential for NO production is high. While numerical calculations of the quick mixer under reacting conditions have been conducted, the hostile environment and lack of appropriate diagnostics have, to date, precluded experimental probing of the reacting case. As an alternative to understanding the effect of geometry and flow variations on the production of NO in the quick mixer, the present paper presents (1) a series of non-reacting parametric studies, and (2) a computational method to extrapolate the results of the non-reacting experiments to reacting conditions. The results show that the rate of NO production is highest in the immediate vicinity of the injection plane. For a given momentum flux ratio between the jets and mainstream, the most effective mixing geometry is that which mixes effectively in both (1) the plane of injection, and (2) the wall regions downstream of the plan of injection. The tailoring of the mixing is key to minimize the NO formed. As a result, the best overall mixer with respect to the minimization of NO production may depend on the system specific characteristics of the particular application.

Hatch, M. S.↗

DOE OSTI2020

Pump-and-Treat Impacts on Aquifer Conditions and the Development of System-Wide Performance Strategies - 20377

The pump-and-treat (P and T) system on the Hanford Site's Central Plateau currently treats multiple contaminants within the 200-ZP-1 operable unit, including nitrate through its biological treatment processes. Although it was initially designed to support the 200-ZP-1 Remedial Action Objectives, the P and T system has evolved in use to address contaminants from other regions of the aquifer as well. The P and T influents are biogeochemically distinct, treating groundwaters with elevated concentrations of cyanide, uranium, technetium-99, and nitrate. Given the varying geochemical signatures from current and potential future sources, operational conditions, and amendments considered for treatment processes, there is a need to identify the impacts that the P and T effluent has on the aquifer, and how the aquifer affects P and T performance. To this end, laboratory efforts have focused on characterizing P and T effluent and its biogeochemical effects on the sediments through a series repacked column experiments. The P and T effluent is rich in particulate matter. A systematic inspection of this particulate matter in the P and T effluent showed significant levels of manganese/iron oxides, calcite crystals, relatively large organic matter molecules, and biomass. Therefore, the column experiments were designed and conducted for four different treatment systems: artificial groundwater, filtered P and T effluent, non-filtered P and T effluent, and chlorinated P and T effluent. Different levels of microbiologically- and geochemically-induced changes in the columns occurred and modified the flow systems. For example, physical filtration occurred in the sediments where the particulate material had accumulated in the top portion of the column. Reactive transport modeling of the laboratory experiments is being carried out so that the reaction network can be extrapolated to the field scale. These simulations will provide predictive evaluations of system performance based on P and T operational changes and aquifer mass loading and capacity estimates. This information can be used to address combined subsurface and operational challenges, such as the need for frequent well redevelopment to maintain injection capacity. This information also provides the technical basis for decisions related to the P and T system operations that support remedy optimization efforts and short- and long-term remedy decisions related to multiple operable units on the Hanford Site Central Plateau. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1984

Effect of creep in titanium alloy Ti-6Al-4V at elevated temperature on aircraft design and flight test

Short-term compressive creep tests were conducted on three titanium alloy Ti-6Al-4V coupons at three different stress levels at a temperature of 714 K (825 F). The test data were compared to several creep laws developed from tensile creep tests of available literature. The short-term creep test data did not correlate well with any of the creep laws obtained from available literature. The creep laws themselves did not correlate well with each other. Short-term creep does not appear to be very predictable for titanium alloy Ti-6Al-4V. Aircraft events that result in extreme, but short-term temperature and stress excursions for this alloy should be approached cautiously. Extrapolations of test data and creep laws suggest a convergence toward predictability in the longer-term situation.

Jenkins, J. M.↗

NASA NTRS2008

Analysis of Plume Effects on Sonic Boom Signature for Isolated Nozzle Configurations

Computational fluid dynamics (CFD) analysis has been performed to study the plume effects on sonic boom signature for isolated nozzle configurations. The objectives of these analyses were to provide comparison to past work using modern CFD analysis tools, to investigate the differences of high aspect ratio nozzles to circular (axisymmetric) nozzles, and to report the effects of underexpanded nozzle operation on boom signature. CFD analysis was used to address the plume effects on sonic boom signature from a baseline exhaust nozzle. Near-field pressure signatures were collected for nozzle pressure ratios (NPRs) between 6 and 10. A computer code was used to extrapolate these signatures to a ground-observed sonic boom N-wave. Trends show that there is a reduction in sonic boom N-wave signature as NPR is increased from 6 to 10. The performance curve for this supersonic nozzle is flat, so there is not a significant loss in thrust coefficient as the NPR is increased. As a result, this benefit could be realized without significant loss of performance. Analyses were also collected for a high aspect ratio nozzle based on the baseline design for comparison. Pressure signatures were collected for nozzle pressure ratios from 8 to 12. Signatures were nearly twice as strong for the two-dimensional case, and trends also show a reduction in sonic boom signature as NPR is increased from 8 to 12. As low boom designs are developed and improved, there will be a need for understanding the interaction between the aircraft boat tail shocks and the exhaust nozzle plume. These CFD analyses will provide a baseline study for future analysis efforts.

Castner, Raymond S.↗

NASA NTRS2008

Analysis of Plume Effects on Sonic Boom Signature for Isolated Nozzle Configurations

Castner, Raymond S.↗

NASA NTRS1976

Low pollution combustor designs for CTOL engines - Results of the Experimental Clean Combustor Program

The NASA/Pratt & Whitney Aircraft Experimental Clean Combustor Program is a multi-year, major contract effort. Primary program objectives are the generation of combustor technology for development of advanced commercial CTOL engines with lower exhaust emissions than current aircraft and demonstration of this technology in a full-scale JT9D engine in 1976. This paper describes the pollution and performance goals, Phase I and II test results, and the Phase III combustor hardware, pollution sampling techniques, and test plans. Best results were obtained with the Vorbix concept which employs multiple burning zones and improved fuel preparation and distribution. Substantial reductions were achieved in all pollutant categories, meeting the 1979 EPA standards for NOx, THC, and smoke when extrapolated to JT9D cycle conditions. The Vorbix concept additionally demonstrated the capability for acceptable altitude relight and did not appear to have unsolvable durability or exit temperature distribution problems.

Roberts, R.↗

NASA NTRS1992

Computational/experimental analysis of three low sonic boom configurations with design modifications

The Euler code, designated AIRPLANE, which uses an unstructured tetrahedral mesh was used to compute near-field sonic boom pressure signatures on three modern low sonic boom configurations: the Mach 2, Mach 3, and Haglund models. The TEAM code which uses a multi-zoned structured grid was used to calculate pressure signatures for the Mach 2 model. The computational pressure signatures for the Mach 2 and Mach 3 models are compared with recent experimental data. The computed pressure signatures were extracted at distances less than one body length below the configuration and extrapolated to the experimental distance. The Mach 2 model was found to have larger overpressures off-ground-track than on-ground-track in both computational and experimental results. The correlations with the experiment were acceptable where the signatures were not contaminated by instrumentation and model-support hardware. AIRPLANE was used to study selected modifications to improve the overpressures of the Mach 2 model.

Cliff, Susan E.↗

NASA NTRS2002

Analytical Verifications in Cryogenic Testing of NGST Advanced Mirror System Demonstrators

Ground based testing is a critical and costly part of component, assembly, and system verifications of large space telescopes. At such tests, however, with integral teamwork by planners, analysts, and test personnel, segments can be included to validate specific analytical parameters and algorithms at relatively low additional cost. This paper opens with strategy of analytical verification segments added to vacuum cryogenic testing of Advanced Mirror System Demonstrator (AMSD) assemblies. These AMSD assemblies incorporate material and architecture concepts being considered in the Next Generation Space Telescope (NGST) design. The test segments for workmanship testing, cold survivability, and cold operation optical throughput are supplemented by segments for analytical verifications of specific structural, thermal, and optical parameters. Utilizing integrated modeling and separate materials testing, the paper continues with support plan for analyses, data, and observation requirements during the AMSD testing, currently slated for late calendar year 2002 to mid calendar year 2003. The paper includes anomaly resolution as gleaned by authors from similar analytical verification support of a previous large space telescope, then closes with draft of plans for parameter extrapolations, to form a well-verified portion of the integrated modeling being done for NGST performance predictions.

Cummings, Ramona↗

NASA NTRS1985

Vortex shedding flowmeters for liquids at high flow velocities

A number of vortex shedding flowmeter designs for flow measurements in liquid oxygen ducts on the space shuttle main engines have been tested in a high head water flow test facility. The results have shown that a vortex shedding element or vane spanning the duct can give a linear response to an average flow velocity of 46 m/s (150 ft/s) in a 1 1/2 inch nominal (41 mm actual) diameter duct while a vane partially spanning the duct can give a linear response to velocities exceeding 55 m/s (180 ft/s). The maximum pressure drops across the flow sensing elements extrapolate to less than 0.7 MPa (100 psi) at 56 m/s (184 ft/s) for liquid oxygen. The test results indicate that the vanes probably cannot be scaled up with pipe size, at least not linearly.

Siegwarth, J. D.↗