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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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NASA NTRS1979

A consistent design procedure for supercritical airfoils in free air and a wind tunnel

A computational inverse procedure for transonic airfoils in which shapes are determined supporting prescribed pressure distributions is presented. The method uses the small disturbance equation and a consistent analysis-design differencing procedure at the airfoil surface. This avoids the intermediate analysis-design-analysis iterations. The effect of any openness at the trailing edge is taken onto account by adding an effective source term in the far field. The final results from a systematic expansion procedure which models the far field for solid, ideal slotted, and free jet tunnel walls are presented along with some design results for the associated boundary conditions and those for a free flight.

Shankar, V.↗

NASA NTRS2013

A Framework for Robust Multivariable Optimization of Integrated Circuits in Space Applications

Application Specific Integrated Circuit (ASIC) design for space applications involves multiple challenges of maximizing performance, minimizing power and ensuring reliable operation in extreme environments. This is a complex multidimensional optimization problem which must be solved early in the development cycle of a system due to the time required for testing and qualification severely limiting opportunities to modify and iterate. Manual design techniques which generally involve simulation at one or a small number of corners with a very limited set of simultaneously variable parameters in order to make the problem tractable are inefficient and not guaranteed to achieve the best possible results within the performance envelope defined by the process and environmental requirements. What is required is a means to automate design parameter variation, allow the designer to specify operational constraints and performance goals, and to analyze the results in a way which facilitates identifying the tradeoffs defining the performance envelope over the full set of process and environmental corner cases. The system developed by the Mixed Signal ASIC Group (MSAG) at the Goddard Space Flight Center is implemented as framework of software modules, templates and function libraries. It integrates CAD tools and a mathematical computing environment, and can be customized for new circuit designs with only a modest amount of effort as most common tasks are already encapsulated. Customization is required for simulation test benches to determine performance metrics and for cost function computation. Templates provide a starting point for both while toolbox functions minimize the code required. Once a test bench has been coded to optimize a particular circuit, it is also used to verify the final design. The combination of test bench and cost function can then serve as a template for similar circuits or be re-used to migrate the design to different processes by re-running it with the new process specific device models. The system has been used in the design of time to digital converters for laser ranging and time-of-flight mass spectrometry to optimize analog, mixed signal and digital circuits such as charge sensitive amplifiers, comparators, delay elements, radiation tolerant dual interlocked (DICE) flip-flops and two of three voter gates.

DuMonthier, Jeffrey↗

NASA NTRS2013

Robust Multivariable Optimization and Performance Simulation for ASIC Design

Application-specific-integrated-circuit (ASIC) design for space applications involves multiple challenges of maximizing performance, minimizing power, and ensuring reliable operation in extreme environments. This is a complex multidimensional optimization problem, which must be solved early in the development cycle of a system due to the time required for testing and qualification severely limiting opportunities to modify and iterate. Manual design techniques, which generally involve simulation at one or a small number of corners with a very limited set of simultaneously variable parameters in order to make the problem tractable, are inefficient and not guaranteed to achieve the best possible results within the performance envelope defined by the process and environmental requirements. What is required is a means to automate design parameter variation, allow the designer to specify operational constraints and performance goals, and to analyze the results in a way that facilitates identifying the tradeoffs defining the performance envelope over the full set of process and environmental corner cases. The system developed by the Mixed Signal ASIC Group (MSAG) at the Goddard Space Flight Center is implemented as a framework of software modules, templates, and function libraries. It integrates CAD tools and a mathematical computing environment, and can be customized for new circuit designs with only a modest amount of effort as most common tasks are already encapsulated. Customization is required for simulation test benches to determine performance metrics and for cost function computation.

DuMonthier, Jeffrey↗

NASA NTRS1978

An algorithm for optimal structural design with frequency constraints

The paper presents a finite element method for minimum weight design of structures with lower-bound constraints on the natural frequencies, and upper and lower bounds on the design variables. The design algorithm is essentially an iterative solution of the Kuhn-Tucker optimality criterion. The three most important features of the algorithm are: (1) a small number of design iterations are needed to reach optimal or near-optimal design, (2) structural elements with a wide variety of size-stiffness may be used, the only significant restriction being the exclusion of curved beam and shell elements, and (3) the algorithm will work for multiple as well as single frequency constraints. The design procedure is illustrated with three simple problems.

Kiusalaas, J.↗

DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1995

Design tool for multiprocessor scheduling and evaluation of iterative dataflow algorithms

A graph-theoretic design process and software tool is defined for selecting a multiprocessing scheduling solution for a class of computational problems. The problems of interest are those that can be described with a dataflow graph and are intended to be executed repetitively on a set of identical processors. Typical applications include signal processing and control law problems. Graph-search algorithms and analysis techniques are introduced and shown to effectively determine performance bounds, scheduling constraints, and resource requirements. The software tool applies the design process to a given problem and includes performance optimization through the inclusion of additional precedence constraints among the schedulable tasks.

Jones, Robert L., III↗

DOE OSTI2021

Recent progress in shattered pellet injection technology in support of the ITER disruption mitigation system*

Shattered pellet injection (SPI) has been selected as the baseline technology for the disruption mitigation (DM) system for ITER. Typical SPI utilizes cryogenic cooling to desublimate low pressure (<100 mbar) gases onto a cold zone within a pipe gun barrel, forming a cylindrical pellet. Pellets are dislodged from the barrel and accelerated using either a gas driven mechanical punch or high-pressure light-gas delivered by a fast-opening valve. SPI technology developed at Oak Ridge National Laboratory is currently deployed and operational on DIII-D, JET, and KSTAR. These SPI systems are used in experiments for physics scaling to ITER thermal mitigation and runaway electron dissipation/avoidance. The pellet sizes used for these machines are in the range of 4 to 12.5 mm in diameter with length to diameter ratios (L/D) of ~1.5. The current plan for ITER SPI is to utilize pellets that are 28.5 mm in diameter with an L/D of ~2. Furthermore, the large pellet sizes, high steady-state magnetic fields, and limitations of operating in a radiation environment render much of the current technology unusable. In addition to technology improvements, a deeper understanding of pellet material properties, formation, and release is being developed for implementation in future SPI designs, specifically ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

A Novel Algorithm for CAD to CSG Conversion in McCAD

Modeling and simulation lie at the heart of the design process of any nuclear application. An accurate representation of the radiation environment ensures not only the feasibility of new technologies, but it also aids in operation, maintenance, and even decommissioning. With increasingly complex designs, high-fidelity models have become a necessity for design maturity. McCAD has been under development for many years at Karlsruhe Institute of Technology (KIT) to facilitate the process of generating suitable models for nuclear analyses. In this paper, an overview of the major advances in the new version of the code is presented. A novel conversion algorithm has proven to be robust in significantly reducing the processing time to generate radiation transport models, making it easier to iterate on design details. A first-of-a-kind capability to generate hierarchical void cells is also discussed with preliminary analysis showing performance gains for particle tracking.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Initial Development of Fusion Magnet Simulation Capabilities for Performance and Safety Evaluation Using the MOOSE Framework

Fusion energy holds the promise of being a transformative technology as a carbon-neutral, sustainable source of energy. Whole device modeling and the development of fusion digital twins will be increasingly important for emerging fusion device concepts at both national laboratories and within the commercial fusion industry. However, meeting the challenge of whole device modeling of fusion energy devices requires robust, multiphysics, multiscale modeling and simulation technologies capable of running on large-scale supercomputers. Detailed analysis of individual systems at-scale is also required to ensure safe and efficient operation as well as provide the safety basis for future device designs and licensing activities. In a tokamak, toroidal and poloidal magnets confine and shape the fusion plasma to promote the fusion reaction. High plasma temperatures and high magnetic field requirements in modern design concepts (leading to high amounts of energy stored within each magnet) impose electrical, thermal, and mechanical loads on the magnet components, which in turn impacts the safety considerations of the magnet and their supporting systems. Idaho National Laboratory (INL) has a history of working in this space, including development and benchmarking of the Magnetic System Circuitry Analysis Program (MSCAP) and Magnet Arcing (MAGARC) codes to study magnet quench events; notably, MAGARC was used to study quenching during the ITER Engineering Design Activity. However, these legacy codes and capabilities are not parallel and scalable, and new tools are required for future advances in this area, which leads to the INL-developed Multiphysics Object-Oriented Simulation Environment (MOOSE) framework. Developed originally for fission reactor systems under United States Department of Energy, Office of Nuclear Energy modeling and simulation programs, the MOOSE framework has been well-suited to multiscale, multiphysics modeling and simulation needs for nuclear systems. The framework is open-source, well-tested, under continuous development and deployment, and developed to a Nuclear Quality Assurance, Level 1 software quality standard. MOOSE has also been used in the fusion space previously in several projects: INL’s Tritium Migration Analysis Program, Version 8 (TMAP8) for tritium migration, UK Atomic Energy Authority’s A Unified Resource for OpenMC (fusion) Reactor Applications (AURORA) code for fusion thermo-mechanical and neutronics analysis, and Argonne National Laboratory’s Cardinal for high-fidelity computational fluid dynamics and neutronics. However, to model superconducting magnets, several MOOSE enhancements are required: additions to the current MOOSE electromagnetic capabilities, new material libraries for superconductors of interest (such as YBCO), as well as fusion-specific models for thermo-mechanics. This talk will discuss initial development activities to build these capabilities in MOOSE, focusing on initial validation and benchmarking activities. Proposed coupling workflows and future work to support the simulation of fusion magnets and magnet structural assemblies for performance and safety evaluation in MOOSE will also be discussed.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2015

Exploring Life Support Architectures for Evolution of Deep Space Human Exploration

Life support system architectures for long duration space missions are often explored analytically in the human spaceflight community to find optimum solutions for mass, performance, and reliability. But in reality, many other constraints can guide the design when the life support system is examined within the context of an overall vehicle, as well as specific programmatic goals and needs. Between the end of the Constellation program and the development of the "Evolvable Mars Campaign", NASA explored a broad range of mission possibilities. Most of these missions will never be implemented but the lessons learned during these concept development phases may color and guide future analytical studies and eventual life support system architectures. This paper discusses several iterations of design studies from the life support system perspective to examine which requirements and assumptions, programmatic needs, or interfaces drive design. When doing early concept studies, many assumptions have to be made about technology and operations. Data can be pulled from a variety of sources depending on the study needs, including parametric models, historical data, new technologies, and even predictive analysis. In the end, assumptions must be made in the face of uncertainty. Some of these may introduce more risk as to whether the solution for the conceptual design study will still work when designs mature and data becomes available.

Anderson, Molly↗

NASA NTRS2015

Exploring Life Support Architectures for Evolution of Deep Space Human Exploration

Anderson, Molly S.↗

DOE OSTI2026

Elevating SolTrace's Capabilities for the Next Generation of Concentrating Solar Analysis

SolTrace is an open-source Monte Carlo ray tracing software developed at NREL. SolTrace can characterize concentrating solar thermal (CST) collector optical performance and is CST technology agnostic. Shown in Fig. 1, SolTrace is a foundational tool in NREL's CST system and component modeling suite. SolTrace's generic surface elements can flexibly model novel collector and receiver designs to predict spatial and temporal flux distributions - critical to understand for CST component design, performance prediction, and system integration. Since its initial development, SolTrace has over 1,650 references on Google Scholar, over 9,800 downloads since 2017, and has served the CST research and development community as a benchmark of 3rd party verification. SolTrace provides users with many options for defining surface shape and boundaries. However, SolTrace provides limited documentation which can result in a steep learning curve for new users. Additionally, SolTrace lacks the computational performance required to evaluate optical performance of a CST system over the course of a year and/or iteratively over design parameters in a timely manner. To address this, we are working towards a new release of SolTrace that enables increased computational throughput by implementing ray tracing acceleration structures and enabling GPU parallelization. Additionally, we are working to improve SolTrace's usability, accessibility, and maintainability by (1) automating solar position time-dependent simulation processes, (2) creating general CST collector templates of grouped elements, (3) updating the user interface to better visualize model inputs and outputs, and (4) creating a user support network through forums, "how to" videos, and documentation.

14 SOLAR ENERGY↗

NASA NTRS1993

Analysis and design of an ultrahigh temperature hydrogen-fueled MHD generator

A coupled gas dynamics/radiative heat transfer analysis of partially ionized hydrogen, in local thermodynamic equilibrium, flowing through an ultrahigh temperature (10,000-20,000 K) magnetohydrodynamic (MHD) generator is performed. Gas dynamics are modeled by a set of quasi-one-dimensional, nonlinear differential equations which account for friction, convective and radiative heat transfer, and the interaction between the ionized gas and applied magnetic field. Radiative heat transfer is modeled using nongray, absorbing-emitting 2D and 3D P-1 approximations which permit an arbitrary variation of the spectral absorption coefficient with frequency. Gas dynamics and radiative heat transfer are coupled through the energy equation and through the temperature- and density-dependent absorption coefficient. The resulting nonlinear elliptic problem is solved by iterative methods. Design of such MHD generators as onboard, open-cycle, electric power supplies for a particular advanced airbreathing propulsion concept produced an efficient and compact 128-MWe generator characterized by an extraction ratio of 35.5 percent, a power density of 10,500 MWe/cu m, and a specific (extracted) energy of 324 MJe/kg of hydrogen. The maximum wall heat flux and total wall heat load were 453 MW/sq m and 62 MW, respectively.

Moder, Jeffrey P.↗

NASA NTRS2019

In-Space Robotic Assembly Joint Characterization Approach

This paper describes the test systems and approaches developed to characterize the performance of a structural joint that is intended for robotic in-space assembly (ISA). The design of the joint is based on a heritage concept from National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) originally intended for structural assembly by astronauts during extravehicular activity (EVA). Its design was modified under a public-private partnership and is intended to accelerate the availability of, and reduce costs for the infusion of NASA developed technologies into commercial ISA systems. Test systems were developed to measure the axial, bending, and torsional stiffness of the joint at a wide range of temperatures. A test system was also developed to measure the reliability of the joint in terms of translation and rotation when disassembled and re-assembled in space. These test systems were used to characterize the joint behavior and provide performance data for the iterative joint design process. The paper also lists the lessons learned to aid testing of next generation robotic in-space assembly joints.

Abraham, Nijo A.↗

NASA NTRS2019

Development Concepts for Mars Ascent Vehicle (MAV) Solid and Hybrid Vehicle Systems

The Advanced Concepts Office (ACO) at Marshall Space Flight Center (MSFC) has conducted ongoing studies and trades into options for both hybrid and solid vehicle systems for potential Mars Ascent Vehicle (MAV) concepts for the Jet Propulsion Laboratory (JPL). Two MAV propulsion options are being studied for use in a potential Mars Sample Retrieval (MSR) campaign. The following paper describes the current concepts for hybrid and solid propulsion vehicles for MAV as part of a potential MSR campaign, and provides an overview of the ongoing studies and trades for both hybrid and solid vehicle system concepts. Concepts and options under consideration for vehicle subsystems include reaction control system (RCS), separation, and structures will be described in terms of technology readiness level (TRL), benefit to the vehicle design, and associated risk. A hybrid propulsion system, which uses a solid fuel core and liquid oxidizer, is currently being developed by JPL with support from MSFC. This type of hybrid propulsion vehicle would allow the MAV to be more flexible at the cost of higher complexity, in contrast to the solid propulsion vehicle that is simpler, but allows less flexibility. The solid propulsion vehicle study performed by MSFC in 2018 further refined the solid propulsion system sizing as well as added definition to vehicle subsystem concepts, including the RCS, structures and configuration, interstage and separation, aerodynamics, and power/avionics. The studies were performed using an iterative concept design methodology, engaging subject matter experts from across MSFC’s propulsion and vehicle systems disciplines as well as seeking trajectory feedback from analysts at JPL.

McCollum, Lisa Tunstill↗

DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Estimation of the Thermal-Fluids and Thermal-Structural Performance of Helium-Cooled Modular Finger-Type Divertors

Over the past decade, our group has investigated the thermal-fluid performance of the helium-cooled modular divertor with multiple jets (HEMJ) and a simplified “flat” design of the HEMJ for long-pulse magnetic fusion energy (MFE) reactors. Experimental studies were performed in a helium (He) loop at the prototypical pressure of 10 MPa, nearly prototypical He temperatures and incident heat fluxes using test sections made from stainless steel and tungsten alloys. Correlations for average Nusselt numbers and pressure loss coefficients were developed from the data and are used to validate computational fluid dynamics (CFD) models. Here, this work presents updated thermal-fluids performance curves based on these correlations that estimate the maximum heat flux that can be accommodated by the plasma-facing surface and coolant pumping power requirements at prototypical operating conditions. Thermal-structural performance curves developed from ITER structural design criteria are introduced, which include protection against ductile and non-ductile failure, ratcheting fatigue, and creep fatigue. The performance design curves for these finger-type divertors demonstrate that the “flat” design, with a significantly less complicated geometry than the HEMJ, has thermal-fluid and thermal-structural performance comparable to the original HEMJ concept, and may be superior in terms of non-ductile failure criteria.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Strategies for connecting whole-building LCA to the low-carbon design process

Abstract Decarbonization is essential to meeting urgent climate goals. With the building sector in the United States accounting for 35% of total U.S. carbon emissions, reducing environmental impacts within the built environment is critical. Whole-building life cycle analysis (WBLCA) quantifies the impacts of a building throughout its life cycle. Despite being a powerful tool, WBLCA is not standard practice in the integrated design process. When WBLCA is used, it is typically either speculative and based on early design information or conducted only after design completion as an accounting measure, with virtually no opportunity to impact the actual design. This work proposes a workflow for fully incorporating WBLCA into the building design process in an iterative, recursive manner, where design decisions impact the WBLCA, which in turn informs future design decisions. We use the example of a negative-operational carbon modular building seeking negative upfront embodied carbon using bio-based materials for carbon sequestration as a case study for demonstrating the utility of the framework. Key contributions of this work include a framework of computational processes for conducting iterative WBLCA, using a combination of an existing building WBLCA tool (Tally) within the building information modeling superstructure (Revit) and a custom script (in R) for materials, life cycle stages, and workflows not available in the WBLCA tool. Additionally, we provide strategies for harmonizing the environmental impacts of novel materials or processes from various life cycle inventory sources with materials or processes in existing building WBLCA tool repositories. These strategies are useful for those involved in building design with an interest in reducing their environmental impact. For example, this framework would be useful for researchers who are conducting WBLCAs on projects that include new or unusual materials and for design teams who want to integrate WBLCA more fully into their design process in order to ensure the building materials are consciously chosen to advance climate goals, while still ensuring best performance by traditional measures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗