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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Experimental Investigations to Study the Effects of Microwave Treatment Strategy on Tool Performance in Turning Operation

In the present study, microwave treatment has been used to enhance the tribological properties of single-point tungsten carbide (WC) cutting tool inserts such as wear resistance and hardness. The tool hardness and cutting parameters were considered to evaluate the performance of microwave-treated WC inserts in turning operation. The optimum cutting parameters were identified using response surface method (RSM)-based desirability approach. The relationship between cutting parameters and output responses, viz. flank wear, cutting force and surface roughness, was developed using the RSM. The investigations revealed that the increase in tool hardness due to complex carbide formation results in a significant reduction in tool wear, cutting forces and improvement in the surface finish of workpiece. Further, the statistical models results were validated with the experimental results. Metallurgical properties of treated and untreated tool inserts were analyzed using scanning electron microscope, x-ray diffraction method and Vickers microhardness tests. The results highlighted the importance of microwave treatment in enhancing the machining performance in turning operation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Component based development of computer-aided tools for different applications

Computer-aided methods and tools are used at different stages of chemical process development. However new tools are needed to meet the current and future challenges through innovative and more sustainable solutions that the currently available tools may not be able to provide. This work focuses on component-based software architecture for development of tailor-made computer-aided tools for specific application objectives. The architecture is based on “components”, which can be model-objects that are stored in a library; collection of property models; databases; numerical solvers; design-algorithms (work-flows) etc. Furthermore, the main idea of these components is to incorporate a plug & play framework, where for a specific purpose, after the work-flow and associated data-flow are established, a specific computer-aided tool can be configured through a library of software components. Also, through the use of software components that are based on predictive model-based solution techniques, the final software can be reliably used to provide innovative and more sustainable solutions over a wide range of problems.

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

Estimation of cutting tool wear using an elastomeric tactile sensor

Machining performance of cutting tools and part quality are affected by the geometric condition of the cutting edge, which is influenced by thermomechanical loads experienced during the process. Tool condition monitoring (TCM) systems provide insight for timely replacement of cutting tools. However, existing TCM systems are expensive and require specialized equipment or sensors, hindering widespread adoption. A novel TCM system is developed herein using an elastomeric tactile sensor. Sensor images of the cutting edge are used to quantify wear using two distinct algorithms. In the first algorithm, the unworn and worn edges are identified based on Canny edge detect. In the second, the unworn edge is identified using edge detection while the region of wear is identified using a relative intensity method. In both cases, the maximum wear width is calculated based on an experimentally determined pixel to-physical distance scale. The TCM system is first used to estimate flank wear on a solid carbide helical end mill before evaluating its robustness by employing it to estimate insert wear of an indexable helical end mill. Measurements are also performed manually using an optical microscope and a high-resolution focus variation microscope for verification. The novel technique estimates flank wear in the solid carbide tool with a high accuracy of 98%. Larger discrepancies are observed for the inserts, however, with overlapping uncertainties. In conclusion, the technique shows promise in adaptability, automation, and closed loop control of machine tools.

Machining↗
DOE OSTI2019

Advanced Simulation Tools for Muon-Based Accelerators

The project developed new software tools incorporating the most accurate theoretical calculations and experimental data available for crucial and not-yet-considered physics processes specific to muon accelerators. These new tools were applied to modeling muon ionization cooling channels for a muon collider or a neutrino factory, the facilities that have the potential to discover and explore new exciting fundamental physics but require the development of demanding technologies and innovative concepts. G4beamline, COSY Infinity, and WARP computer codes are particularly well-suited for addressing muon accelerator modeling problems. G4beamline was chosen for its flexibility and modularity, and for being one of the de facto standard codes used by the muon accelerator community. COSY was selected for speed, ability to take into account high-order nonlinear effects essential for the large beams under consideration, and availability of built-in optimization tools. WARP was chosen for its space charge calculation capabilities, speed and flexibility of implementing new lattice elements such as RF cavities. This final technical report summarizes the efforts on implementing advanced new tools in these computer codes addressing the shortcomings in modeling muon physics processes and using these tools to model muon ionization cooling channels.

43 PARTICLE ACCELERATORS↗
NASA NTRSDate not supplied

RABBIT: A Rapid Low Fidelity BVI Prediction Tool—Comparison and Validation using the NASA RVLT Toolchain

Rotorcraft noise source identification is at the forefront of civil rotorcraft applications with the emergence of the Urban Air Mobility (UAM) market. Blade Vortex Interaction (BVI) has been identified as one key source of noise produced by a rotor. To predict BVI occurrences for various Urban Air Mobility (UAM) configurations, the RApid Blade and Blade-Vortex InTeraction (RABBIT) tool was developed and utilized. The tool is built from a Beddoes Wake Model, and computes variables such as miss distance and BVI angle to calculate an impulse factor, which is able to visualize BVI for a given vehicle and flight condition. A complete checkout of this tool and comparison with CAMRADII and ANOPP2/AARON, is performed. A wake comparison between RABBIT and CAMRADII is presented, and BVI is compared with ANOPP2/AARON’s acoustic pressure time history to verify the tools effectiveness and accuracy. Three NASA Revolutionary Vertical Lift Technology (RVLT) concept vehicles were analyzed with increasing geometric and aerodynamic complexity, including the Quiet Single Main Rotor (QSMR), Side-by-Side, and Quadrotor. An analysis of the results concludes that RABBIT presents a low-fidelity tool that accurately predicts BVI location and intensity for multiple vehicle configurations and various flight conditions.

RABBIT↗
DOE OSTI2024

Navigating the Compliance Reporting Tool: EPAct State and Alternative Provider Fleet Program User Guide

State government and alternative fuel provider fleets covered under the State and Alternative Fuel Provider Fleet Program (Program) established pursuant to the Energy Policy Act of 1992 (EPAct) may use the Compliance Reporting Tool to track and report on several compliance activities. These activities include, but are not limited to, completing Standard Compliance annual reports, Alternative Compliance notices of intent, and exemption requests. Covered fleets can access the Compliance Tool through the Program's website at https://epact.energy.gov/users/sign_in. Covered fleet point of contacts should bookmark the Compliance Reporting Tool for future access. This user guide addresses general tool navigation, including: 1) Logging in to the Tool, 2) Managing Your Point of Contact and Account Information, 3) Managing Fleet Contact Information, 4) Adding New Fleets to Your Account, 5) Reporting for Entities With Multiple Fleets, and 6) Viewing Credit Trades.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
DOE OSTI2017

Simultaneous Independent Control of Tool Axial Force and Temperature in Friction Stir Processing

Maintaining consistent tool depth relative to the part surface is a critical requirement for many Friction stir processing (FSP) applications. Force control is often used with the goal of obtaining a constant weld depth. When force control is used, if weld temperature decreases, flow stress increases and the tool is pushed up. If weld temperature increases, flow stress decreases and the tool dives. These variations in tool depth and weld temperature cause various types of weld defects. Robust temperature control for FSP maintains a commanded temperature through control of the spindle axis only. Robust temperature control and force control are completely decoupled in control logic and machine motion. This results in stable temperature, force and tool depth despite the presence of geometric and thermal disturbances. Performance of this control method is presented for various weld paths and alloy systems.

force control↗
DOE OSTI2018

Influence of Laser Surface Texturing on Tribological Performance of Tool Steels

This paper deals with the influence of laser surface texturing on tribological performance of two different tool steels: (a) Böhler K100 produced by conventional production technology and (b) Böhler K390 Microclean{sup ®} produced by powder metallurgy. The surface of heat-treated tool steels was modified using three different texture patterns. Impact of laser surface texturing was analyzed after different treatments. Furthermore, selected samples were borided to evaluate the combined influence of laser surface texturing and boriding on tribological performance of surface-treated samples. The results show that boriding was not beneficial for wavy surface type, and the steel production technology had a certain influence on the spinning tool. The laser surface texturing had an effect on decreasing the coefficient of friction on the K100 tool steel; however, it did not influence the tribological performance of the K390 Microclean{sup ®} tool steel. Boriding process was efficient in decreasing the coefficient of friction for both steels. The low coefficient of friction values did not have a positive influence on the wear depth.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Tool Offset and Rotational Speed in Dissimilar Friction Stir Welding of AISI 304 Stainless Steel and Mild Steel

In the present study, dissimilar friction stir welding was carried out between stainless steel (UNS S30400) and mild steel (UNS G10080) plates of 4 mm thickness using a tungsten carbide tool. The influence of tool rotational speeds (600, 875 rpm) and tool offsets (0.6, 1.2 mm) on mechanical properties, i.e., hardness, tensile strength, and impact toughness of welded joints was investigated. Maximum tensile strength of the joint was about 107.6% of the mild steel under rotational speed of 875 rpm and tool offset of 1.2 mm. The maximum hardness reached in the stir zone was about 281 HV{sub 0.5} due to the phase transformations and grain refinement. Charpy’s notch toughness of the welded joints was observed lower than the base materials. The microstructural characterizations were carried by using an optical microscope, and FESEM–EDS analysis which revealed the complex material mixing and material movement during the welding. Tungsten-rich bands were observed in the weld micrograph especially toward the advancing side. During this study, various wear mechanisms like oxidation wear, abrasive wear, and adhesion wear were responsible for the degradation of tungsten carbide tool.

36 MATERIALS SCIENCE↗
DOE OSTI2024

3D printed carbon fiber reinforced carbon as an energy efficient alternative to graphite for EFAS tooling

As Electric Field Assisted Sintering (EFAS) gains more industrial acceptance and use, it becomes more important to develop more efficient means to implement this technology. To this aim, 3D printed continuous carbon fiber reinforced carbon (CCC) was manufactured and fabricated into tooling for EFAS systems as an alternative to traditional graphite tooling. The impact of fiber orientation on the thermal and electrical properties of the CCC was characterized. Sample material was sintered in Tokai G535 graphite tooling, under common processing conditions and compared with CCC tooling. There was nearly 50 % energy savings compared to graphite while maintaining equivalent sample density and microstructure plus keeping ram temperatures 39 % cooler. This is due to spatial control of generated heat and thermal diffusivity within the molds, by means of fiber orientation anisotropy. Finite element modeling of the tooling design supported the experimental results as well as displays the effect of optimization of this 3D printed CCC material.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A dataset of eco-evidence tools to inform early-stage environmental impact assessments of hydropower development

The datasets described herein provide the foundation for a decision support prototype (DSP) toolkit aimed at assisting stakeholders in determining evidence of which aspects of river ecosystems have been impacted by hydropower. The DSP toolkit and its application are presented and described in the article “Evidence-based indicator approach to guide preliminary environmental impact assessments of hydropower development” [1]. Development of the DSP and the output for decision support centralize around 42 river function indicators describing the dimensionality of river ecosystems through six main categories: biota and biodiversity, water quality, hydrology, geomorphology, land cover, and river connectivity. Three main tools are represented in the DSP: A science-based questionnaire (SBQ), an environmental envelope model (EEM), and a river function linkage assessment tool (RFLAT). The SBQ is a structured survey-style questionnaire whose objective is to provide evidence of which indicators have been impacted by hydropower. Based on a global literature review, 140 questions were developed from general hypotheses regarding the impacts of dams on rivers. The EEM is a model to predict the likelihood of hydropower impacting indicators based on a several variables. The intended use of the EEM is for situations of new hydropower development where results of the SBQ are incomplete or highly uncertain. The EEM was developed through the compilation of a dataset containing attributes of dams, reservoirs, and geospatial information on environmental concerns, which was combined with data on ecological indicators documented at those sites through literature review. The model operates through 247 “envelopes” and weighting factors, representing the individual effect of each variable on each indicator, all available through spreadsheets. Finally, the RFLAT is a tool to examine causal relationships amongst indicators. Inter-indicator relationships were hypothesized based on literature review and summarized into node and edge datasets to represent the structure of a graphical network. Bayes theorem was used estimate conditional probabilities of inter-indicator relationships based on the output of the SBQ. Nodes and edges were imported into R programming environment to visualize ecological indicator networks. The datasets can be expanded upon and enriched with more detailed questions for the SBQ, building upon the EEM with to develop more sophisticated models, and identifying new relationships for the RFALT. Additionally, once the tools are applied to numerous hydropower developments, the output of the tools (e.g. evidence of impacted indicators) becomes a very useful dataset for meta-analyses of hydropower impacts.

13 HYDRO ENERGY↗
DOE OSTI2014

Bridging the gap between LCA, LCC and CBA as sustainability assessment tools

Increasing interest in sustainability has led to the development of sustainability assessment tools such as Life Cycle Analysis (LCA), Life Cycle Costing (LCC) and Cost–Benefit Analysis (CBA). Due to methodological disparity of these three tools, conflicting assessment results generate confusion for many policy and business decisions. In order to interpret and integrate assessment results, the paper provides a framework that clarifies the connections and coherence between the included assessment methodologies. Building on this framework, the paper further focuses on key aspects to adapt any of the methodologies to full sustainability assessments. Aspects dealt with in the review are for example the reported metrics, the scope, data requirements, discounting, product- or project-related and approaches with respect to scarcity and labor requirements. In addition to these key aspects, the review shows that important connections exist: (i) the three tools can cope with social inequality, (ii) processes such as valuation techniques for LCC and CBA are common, (iii) Environmental Impact Assessment (EIA) is used as input in both LCA and CBA and (iv) LCA can be used in parallel with LCC. Furthermore, the most integrated sustainability approach combines elements of LCA and LCC to achieve the Life Cycle Sustainability Assessment (LCSA). The key aspects and the connections referred to in the review are illustrated with a case study on the treatment of end-of-life automotive glass. - Highlights: • Proliferation of assessment tools creates ambiguity and confusion. • The developed assessment framework clarifies connections between assessment tools. • Broadening LCA, key aspects are metric and data requirements. • Broadening LCC, key aspects are scope, time frame and discounting. • Broadening CBA, focus point, timespan, references, labor and scarcity are key.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

QUIC-fire: A fast-running simulation tool for prescribed fire planning

Coupled fire-atmospheric modeling tools are increasingly used to understand the complex and dynamic behavior of wildland fires. Multiple research tools linking combustion to fluid flow use Navier-Stokes numerical solutions coupled to a thermodynamic model to understand fire-atmospheric feedbacks, but these computational fluid dynamics approaches require high-performance computing resources. We present a new simulation tool called QUIC-Fire to rapidly solve these feedbacks by coupling the mature 3-D rapid wind solver QUIC-URB to a physics-based cellular automata fire spread model Fire-CA. QUIC-Fire uses 3-D fuels inputs similar to the CFD model FIRETEC, allowing this tool to simulate effects of fuel structure on local winds and fire behavior. Results comparing fire behavior metrics to the computational fluid dynamic model FIRETEC show strong agreement. As a result, QUIC-Fire is the first tool intended to provide an opportunity for prescribed fire planners to compare, evaluate and design burn plans, including complex ignition patterns and coupled fire atmospheric feedbacks.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Integration of discrete-event dynamics and machining dynamics for machine tool: Modeling, analysis and algorithms

Machining dynamics research lays a solid foundation for machining operations by providing stable combinations of spindle speed and depth of cut. Furthermore, machine learning has been applied to predict tool life as a function of cutting speed. However, the existing research does not consider the discrete-event dynamics in machine shop, i.e., the machine tool needs to process a series of parts in queue under various practical production requirements. This paper addresses the integration of discrete-event dynamics and machining dynamics to achieve cost savings in machining. A learning-based cost function is first proposed for the studied integrated optimization problem of machine tool. The proposed cost function utilizes the predicted tool life under different stable cutting speeds for further optimizing speed selection of machine tool to deal with the discrete-event dynamics in machine shop. Then, according to the practical production requirements, effective mathematical optimization models are developed for the related integrated optimization problems with the consideration of cost, makespan and due date, respectively. Numerical results show the effectiveness of our proposed methods and also the potential to be used in practice.

Ma, Mason↗
DOE OSTI2021

Logistic classification for tool life modeling in machining

This paper describes the application of logistic classification for tool life modeling and prediction in an industrial setting using shop floor data. Tool life is treated as a classification problem since tool wear can only be measured at the time of tool replacement in a production environment. Laboratory tool wear experiments are used to simulate shop floor wear data by two states: not worn (class 0); and worn (class 1). To incorporate non-linearity in logistic classification, a log-transformation of input features is performed. The logistic classification approach, results, and interpretability of the logistic model are presented.

Karandikar, Jaydeep↗
DOE OSTI2024

A deep learning-based battery sizing optimization tool for hybridizing generation plants

Hybrid generation and energy storage systems offer the ability to increase flexibility of the combined asset. This flexibility can be used to increase provision of services already provided by the generation asset, such as timing sale of electricity to the energy market during high price periods, and also enable provision of additional services, such as ancillary services or contribute to resource adequacy. From a generation asset owner perspective, the decision to hybridize includes selecting an energy storage system that, among other factors, maximizes financial performance of the energy storage investment. Yet, existing tools to optimize energy storage sizing are either too rudimentary (i.e., based on “rules of thumb”) or too complex to implement (i.e., require specialized engineering and software knowledge and a high-performance computer to run). This work presents a novel deep learning-based battery sizing optimization tool that is designed to help generation asset owners easily assess preliminary sizing considerations for potential battery investments to hybridize their generation facility. The tool uses deep learning to predict revenue over a broad search space of potential battery sizes, estimates capital and operating costs (including accounting for battery degradation), and computes financial performance of each potential battery system investment, recommending a system with maximum financial performance. The tool is tested and validated for hydropower assets. Finally, this tool will help a greater cross-section of industry consider investments in battery systems, increasing their revenue and helping them compete in rapidly evolving electrify markets.

13 HYDRO ENERGY↗
DOE OSTI2019

Comparison of biofuel life-cycle GHG emissions assessment tools: The case studies of ethanol produced from sugarcane, corn, and wheat

The use of alternative fuels, particularly bio-based fuels, has been an important strategy to achieve greenhouse gas (GHG) emission reductions compared to petroleum-based fuels. However, discrepancies between results obtained by using different attributional life-cycle assessment (LCA) tools have challenged the credibility of the individual assessments, and as result, the progress towards or compliance with GHG mitigation targets. The objective of this study was to identify the main differences and commonalities in methodological structures, calculation procedures, and assumptions for the major commercial biofuel, ethanol, across three public LCA tools, BioGrace (EU), GHGenius (Canada), and GREET (U.S.), and a research-oriented fourth, the Virtual Sugarcane Biorefinery (VSB), a Brazilian platform for sugarcane ethanol assessments. The calculated emissions across models ranged from 16 to 45 for sugarcane, 43-62 for corn, and 45-68 g CO 2 eq MJ -1 for wheat ethanol. Harmonizing the three public models with VSB assumptions for sugarcane ethanol produced in Brazil, the range was reduced to 16-17 g CO 2 eq MJ -1 for sugarcane ethanol. Agricultural production (e.g., N 2 O emissions from fertilizers; energy and fuel use; straw field-burning; and limestone application) and ethanol shipping were found to be the major causes for variations for differences calculated for sugarcane ethanol. Similarly, harmonizing BioGrace and GHGenius calculations using GREET assumptions for U.S. corn ethanol generated nearly identical results (models varied within a 3% range). The coproduct treatment method was found to be the most influential parameter in the variations calculated for both corn and wheat ethanol. The application of the tools as part of GHG emissions accounting requirements is often defined via regulations and differences and/or conflicting assumptions set-forth in these models lead to most differences observed. Our study provides recommendations for promoting transparency in LCA calculations and assumptions across the tools used in research and development or for regulatory tools regarding biofuels.

09 BIOMASS FUELS↗