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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Design and scale-up of 3D printed bat houses with biomass-derived polymer composites

Biomass (e.g., pine sawdust, especially high–ash content pine sawdust) is commonly disposed of as waste. Combining biomass with polymers to make composite feedstocks for 3D printing has been explored as a method to reduce or repurpose the biomass waste. Although not all biocomposite properties are known, the wood-based polylactic acid (PLA) composite has promising qualities for applications in ecological settings. In this work, pine wood–PLA composite feedstock was used to 3D print supplemental roost structures for endangered tree-roosting bats, which often face a paucity of suitable naturally occurring roosts. This material combination was selected because it is estimated to degrade faster than the synthetic material systems that are used widely in supplemental bat roosting structures to aid in the conservation of tree roosting bats. The layered, rough surface created by the 3D printing process serves as a surface that bats can grip while roosting. Computer-aided design (CAD) models were generated based on natural roost structures, and a full-size bat house was successfully additively manufactured using a pellet-fed large-scale 3D printing system. The 3D printed hexagon exhibited a tensile strength of 22–23 MPa and a Young’s modulus of 3202–3218 MPa in the x-direction. It has been demonstrated that the 3D printed bat house can be installed on a tree in a stable fashion. This successful demonstration of a bat roost manufactured using a bioderived composite should promote its use in other fish and wildlife structures and broader industrial applications such as construction and automobiles.

3D printing↗
DOE OSTI2018

Low pressure direct injection strategies effect on a small SI natural gas two-stroke engine’s energy distribution and emissions

This paper examines methods to simultaneously improve efficiency and reduce emissions from a 34 cc air-cooled two-stroke engine configured to operate on natural gas, using tuned intake plus exhaust resonators designed from Helmholtz resonance theory to promote effective scavenging. The engine was developed for novel application in a small, free piston engine for decentralized power generation. Operation occurred at wide-open-throttle at a speed of 5400 RPM for both port injection (PI) and low-pressure direct injection (LPDI). In both cases, the electronic ignition timing was adjusted for maximum brake torque, while the fuel was adjusted such that both rich and lean combustion were examined. The LPDI engine was then operated over a variety of engine speeds. An energy balance was completed for both PI and LPDI operation, which quantified all energy pathways, as engine operating regimes changed. Results showed that exhaust chemical energy (ECE) for LPDI was reduced significantly when compared to PI, mostly due to less fuel slip. The fuel slip rate ranged from 35 to 40% for PI operation while it was in the range of 6–20% for LPDI operation. However, mixture stratification with LPDI operation increased carbon monoxide emissions. The start-of-injection (SOI) was also examined, targeting a SOI to provide the highest trapping efficiency and most stable combustion. For LPDI operation, trapping efficiency, which is function of engine speed, showed significant effects on overall efficiency and fuel slip. Air volumetric efficiency increased due to the absence of gaseous fuel within the intake manifold. It was shown that, relative to PI, the overall engine indicated efficiency increased by 90% to a maximum indicated efficiency of 30% for LPDI operation with a SOI of 180 CAD BTDC.

42 ENGINEERING↗
DOE OSTI2016

Inhibition of FGF signaling accelerates neural crest cell differentiation of human pluripotent stem cells

Neural crest (NC) is a transient population, arising during embryonic development and capable of differentiating into various somatic cells. The defects of neural crest development leads to neurocristopathy. Several signaling pathways were revealed their significance in NC cell specification. Fibroblast growth factor (FGF) is recognized as an important signaling during NC development, for instance Xenopus and avian; however, its contributions in human species are remained elusive. Here we used human pluripotent stem cells (hPSCs) to investigate the consequences of FGF inhibition during NC cell differentiation. The specific-FGF receptor inhibitor, SU5402, was used in this investigation. The inhibition of FGF did not found to affect the proliferation or death of hPSC-derived NC cells, but promoted hPSCs to commit NC cell fate. NC-specific genes, including PAX3, SLUG, and TWIST1, were highly upregulated, while hPSC genes, such as OCT4, and E-CAD, rapidly reduced upon FGF signaling blockage. Noteworthy, TFAP-2α, a marker of migratory NC cells, abundantly presented in SU5402-induced cells. This accelerated NC cell differentiation could be due to the activation of Notch signaling upon the blockage of ERK1/2 phosphorylation, since NICD was increased by SU5402. Altogether, this study proposed the contributions of FGF signaling in controlling human NC cell differentiation from hPSCs, the crosstalk between FGF and Notch, and might imply to the influences of FGF signaling in neurocristophatic diseases.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

FABP4 induces asthmatic airway epithelial barrier dysfunction via ROS-activated FoxM1

Highlights: • FABP4 plays an important role in airway inflammatory cytokine production and airway barrier integrity. • FoxM1 is an important participant in FABP4-induced airway inflammation and epithelial barrier dysfunction. • Upregulated ROS induced by FABP4 is of significance in activating FoxM1. Functional abnormal airway epithelial cells, along with activated inflammatory cells, resulting in chronic airway inflammation, are considered as the characteristic of asthma. Fatty Acid Binding Protein 4 (FABP4) takes part in glucose and lipid homeostasis, and also have an important role in allergic airway inflammation. However, whether FABP4 influence barrier function of airway epithelial cells is unknown. In vivo, a HDM-induced murine model of asthma was obtained to assessed airway inflammation and protein expression of E-cadherin and Forkhead Box M1 (FoxM1). In vitro, 16-HBE was cultured and was treated with hrFABP4, siFABP4, FABPF4 inhibitor BMS, or FoxM1 inhibitor RCM-1. IL-4, IL-5, and IL-13 level was determined by ELISA. Transepithelial electrical resistance (TER), paracellular permeability and E-cadherin-special immunofluorescence were measured to value airway epithelial barrier function. Intracellular ROS production was determined by DCF-DA fluorescence. FABP4 inhibitor BMS alleviate airway inflammation and destruction of E-cad in allergic mouse. Treatment with HDM or hrFABP4 aggravated inflammatory response, damaged airway epithelial barrier, which could be inhibited by siFABP4 and BMS. Treatment with HDM or hrFABP4 also enhanced levels of FoxM1, and Inhibited FoxM1 suppressed HDM- and hrFABP4-induced inflammation and airway epithelial barrier dysfunction. In addition, H{sub 2}O{sub 2} promoted FoxM1 expression, HDM and hrFABP4 induced-FoxM1 could be inhibited by NAC, leading to decreased inflammation and improved airway epithelial barrier. Upregulated ROS induced by FABP4 was of significance in activating FoxM1 leading to airway inflammation and epithelial barrier dysfunction.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

GhUMC1, a blue copper-binding protein, regulates lignin synthesis and cotton immune response

Highlights: • Knock-down of GhUMC1 attenuates the cotton immune response. • GhUMC1 has a spatio-temporal regulation in cotton disease resistance. • GhUMC1 acts upstream of lignin synthesis and is involved in cell wall remodeling. Verticillium wilt caused by the soil-borne fungus Verticillium dahliae is a serious problem for the sustainable production of cotton. The mechanism of cotton resistance to V. dahliae is unclear, which makes it is difficult to improve cotton resistance breeding. In this study, we characterized an umecyanin-like gene GhUMC1 in cotton, which is homologous to the AtBCB gene in Arabidopsis. It is predominantly expressed in roots and responds to pathogen infection. Knock-down of GhUMC1 increases plant susceptibility to V. dahliae. Expression levels of genes in the JA and SA signaling pathways in roots were down-regulated in GhUMC1-silenced plants. The transcripts of lignin synthesis genes, such as C4H, HCT, CCoAOMT and CAD, were also decreased in GhUMC1 knock-down seedlings, as was lignin content. Interestingly, knock-down of the GhUMC1 also decreased the contents of H{sub 2}0{sub 2} compared with the control. Our results suggest that GhUMC1 is involved in cotton resistance to V. dahliae by the regulation of the JA signaling pathway and lignin metabolism.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

Adherens junction-associated pores mediate the intercellular transport of endosomes and cytoplasmic proteins

Highlights: • We demonstrated the presence of AJ-associated pores with MTs traversing through the pores. • Live imaging allows direct visualization of vesicles being transported through the AJ-associated pores. • The dimerized vesicle-kinesin complexes move across AJs into the neighboring cell. • Most epidermal cells form dorsoventral-oriented two-cell syncytia. Intercellular endosomes (IEs) are endocytosed vesicles shuttled through the adherens junctions (AJs) between two neighboring epidermal cells during Drosophila dorsal closure. The cell-to-cell transport of IEs requires DE-cadherin (DE-cad), microtubules (MTs) and kinesin. However, the mechanisms by which IEs can be transported through the AJs are unknown. Here, we demonstrate the presence of AJ-associated pores with MTs traversing through the pores. Live imaging allows direct visualization of IEs being transported through the AJ-associated pores. By using an optogenetic dimerization system, we observe that the dimerized IE-kinesin complexes move across AJs into the neighboring cell. The AJ-associated pores also allow intercellular movement of soluble proteins. Importantly, most epidermal cells form dorsoventral-oriented two-cell syncytia. Together, we present a model in which an AJ-associated pore mediates the intercellular transport of IEs and proteins between two cells in direct contact.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

LayTracks3D: A new approach for meshing general solids using medial axis transform

This study presents an extension of the all-quad meshing algorithm called LayTracks to generate high quality hex-dominant meshes of general solids. LayTracks3D uses the mapping between the Medial Axis (MA) and the boundary of the 3D domain to decompose complex 3D domains into simpler domains called Tracks. Tracks in 3D have no branches and are symmetric, non-intersecting, orthogonal to the boundary, and the shortest path from the MA to the boundary. These properties of tracks result in desired meshes with near cube shape elements at the boundary, structured mesh along the boundary normal with any irregular nodes restricted to the MA, and sharp boundary feature preservation. The algorithm has been tested on a few industrial CAD models and hex-dominant meshes are shown in the Results section. Work is underway to extend LayTracks3D to generate all-hex meshes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

U-splines: Splines over unstructured meshes

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

42 ENGINEERING↗
DOE OSTI2024

Nonlinear elasticity with the Shifted Boundary Method

Here, we propose a new unfitted/immersed computational framework for nonlinear solid mechanics, which bypasses the complexities associated with the generation of CAD representations and subsequent body-fitted meshing. This approach allows to speed up the cycle of design and analysis in complex geometry and requires relatively simple computer graphics representations of the surface geometries to be simulated, such as the Standard Tessellation Language (STL format). Complex data structures and integration on cut elements are avoided by means of an approximate boundary representation and a modification (shifting) of the boundary conditions to maintain optimal accuracy. An extensive set of computational experiments in two and three dimensions is included.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Adaptive simulations enable computational design of electron beam processing of nanomaterials with supersonic micro-jet precursor

Focused Electron Beam Induced Processing (FEBIP) is a powerful tool for the “direct-write” of nanomaterials with the possibility of atomistic control on suspended 2D material substrates. FEBIP capabilities have been significantly expanded by using a localized jet-based delivery of precursors, and especially when a thermally energized supersonic micro-jet enhances the delivery of mass flux along with controlling the far-from-equilibrium thermodynamic state of adsorbed adatoms. The possibilities of growing nanomaterials with “dialed-in” composition with ultra-high growth rates and aspect ratios up to 100:1 have been demonstrated using the supersonic micro-jet-FEBIP. Bringing this scientific discovery to the level of maturity required for practical applications in additive nanomanufacturing requires simulation tools that are capable of capturing the complex flow physics of micro-jet-substrate interactions that bridge a wide range of flow regimes from the high-density gas micro-jet expanding into the vacuum environment of FEBIP. To address this significant computational challenge, a new approach has been developed and described in this work for a multiscale adaptive DSMC (Direct Simulation Monte Carlo) algorithm to predict the micro-jet gas dynamics in an FEBIP environment, spanning the full range of flow regimes from low Knudsen (Kn) number O(0.01) continuum flow to high Kn of O(10) for the molecular flow within a unified computational framework. Here, the fundamental principles of the adaptive DSMC algorithm are described, its viability as a DSMC technique is demonstrated, and computational improvements for the benchmark cases are discussed in the context of advancing 3D nanofabrication with FEBIP. Ultimately, combining the first principle simulations via adaptive DSMC with the complementary experimental data will enable the creation of the powerful CAD tools for in silico design and optimal operation of micro-jet-FEBIP.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Adaptive workflow for simulation of RF heaters

Accurate RF (Radio Frequency) simulations of fusion systems like ITER require the definition of high-fidelity analysis geometries that include detailed antenna, reactor wall, and physics regions. Here, this paper will describe a workflow for the execution of adaptive high-performance simulations of RF fusion systems. In this workflow, the simulation input consists of a CAD model attributed with the needed analysis attributes. The analysis mesh is automatically generated and the analysis steps are executed using the time-harmonic Maxwell's equations solved using high-order Nédélec finite elements. A patch recovery-based error estimator is used to drive a conforming mesh adaptation procedure.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

An optimization method for flexural bearing design for high-stroke high-frequency applications

A method for optimization of a high-stroke, high-frequency flexural bearing was completed. The main goal was to design a flexural bearing system as the energy restoration component of a one kW free piston linear engine alternator (LEA) operating at 90 Hz and maximum targeted displacement of 22 mm. Defined electricity output of 1 kW, with more than 30% efficiency, required engine operation under high speed and high stroke conditions. Under such challenging stroke and frequency requirements, a method of design was required to select between a wide range of parameters in flexural bearing design. A parametric CAD model was prepared and used in the optimization package of a finite element analysis (FEA) software. Four main parameters of flexural bearing geometry were identified and included the outer diameter, thickness, number of arms, and sweep angle of spiral cuts. Other design parameters including spiral gap width, shape factor and spiral start points angle were shown to be less important compared to these four main parameters in primary design and were examined separately. A neural network algorithm was used to investigate the interactions and effects of design parameters. The sensitivity of each parameter on output criteria such as maximum stress and natural frequency was examined and design charts developed. Methods for further modification of the spiral curve at end points were introduced to reduce the maximum stress level by up to 20%. Several steel alloys and a titanium-based alloy were identified as proper material candidates for high cycle applications and the final designed spring was manufactured and tested to validate the FEA results of axial stiffness and strain level throughout the flexure arms. The percent of the flexure’s moving mass was estimated to be 29% with FEA analysis and compared well with the experimental value of 31%. The stress/strain results of the FEA analysis matched with the experimental results – within ±5%.

42 ENGINEERING↗
DOE OSTI2026

Dataset describing two reference models for full-spectral lighting and daylight simulations together with implementations for two software systems

A dataset of two spectral lighting simulation reference models - one office and one factory hall - is presented. It aims to demonstrate and support full-spectral daylight and electric lighting simulations and facilitate evaluation of non-visual effects of light. The dataset includes Rhino CAD geometry, comprehensive spectral material and light source data and window system BSDF data. Example implementations in the two software tools, Radiance and OWL, enable reproducible workflows and support adoption in other software. The dataset is openly available on Zenodo. The office model reproduces Room 518 at the University of Innsbruck, including a west-facing façade and interior furnishings. The factory hall model follows the proposed geometry in the European standard 15193 for building energy performance. Interior reflectances in the office were measured in-situ using a handheld spectrometer. Exterior spectra and factory hall materials matching specified reflectances were obtained from an online spectral materials database. Glazing transmittance was derived from IGDB data using LBNL Optics/WINDOW. BSDFs for venetian blinds at various tilt angles, and for a diffusing pane adapted from the Complex Glazing Database, were generated in WINDOW. Luminaires in both models are specified with photometric files (Eulumdat/IES) and lamp spectra (Fluorescent 840, 4000 K LED). The provided example implementations (Radiance, OWL) include prepared input data and scripts to run first spectral simulations; example results are also included. The dataset is prepared to support reuse by researchers, designers and software developers for method validation, software engineering and comparison, and development of spectral metrics and controls.

Geisler-Moroder, David↗
DOE OSTI2021

Building envelope anomaly characterization and simulation using drone time-lapse thermography

Defects in building envelopes deteriorate over time without being visible to the human eye, while significantly impacting energy performance due to unaccounted heat transfer. Defects can be characterized in the infrared (IR) spectrum. However, IR readings are typically recorded at singular points in time, when in several cases anomalies can only be revealed at specific times of the day, possibly in different seasons of the year. This paper presents a novel workflow for 3D envelope defect characterization and modeling using aerial time-lapse IR data collection using drones. A comprehensive envelope thermal profile is developed for a case study building employing the photogrammetry software Agisoft Photoscan, which generates temporal IR inspections of building skins using multiple thermography orthomosaics. Point-cloud data is then translated into a CAD model and thermal zones for whole Building Energy Modeling (BEM) using Honeybee as a frontend to EnergyPlus to showcase the potential of inclusion of detailed 4D data. Envelope contributions in this case study’s anomalies showed heat losses of 6447.6 kWh, and Energy Use Intensity (EUI) differences of ~2 kWh/m 2 /year from the baseline. Finally, why there is currently little translation of this work in BEM software is discussed, while identifying limitations and future research in the employment of time-lapse thermography using drones for more accurate building envelope inspection and modeling.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Numerical analysis of soot emissions from gasoline-ethanol and gasoline-butanol blends under gasoline compression ignition conditions

In the present work, computational fluid dynamics (CFD) simulations of a single-cylinder gasoline compression ignition (GCI) engine were performed to investigate the impact of blending two biofuels, ethanol and n-butanol, with gasoline on the trade-off between combustion phasing and soot emissions under low load conditions. Here, in order to represent market gasoline (RD5-87), a four-component toluene primary reference fuel (TPRF) + ethanol (ETPRF) surrogate (with 20% ethanol by mole; E20) was formulated using a neural network based octane predictor such that the surrogate had the same ethanol content, Research Octane Number (RON) and Octane Sensitivity (S). In addition, a novel skeletal kinetic mechanism for ETPRF and TPRF + n-butanol (BTPRF) blends, incorporating polycyclic aromatic hydrocarbon (PAH) chemistry, was developed. A three-dimensional (3D) engine CFD formulation employing the skeletal mechanism, adaptive mesh refinement (AMR), finite-rate chemistry approach, and hybrid method of moments (HMOM) was adopted to capture the in-cylinder combustion phenomena and soot emissions. The engine CFD model was validated against RD5-87 experimental data for a broad range of start-of-injection (SOI) timings (-21/-27/-36/-45 crank angle degrees (CAD) after top-dead center (aTDC)), with respect to in-cylinder pressure, heat release rate, combustion phasing, and soot emissions. The closed-cycle simulation results were analyzed to elucidate the non-monotonic trend of soot emissions versus SOI timing: SOI-36 > SOI-45 > SOI-21 > SOI-27. Thereafter, the validated CFD model was employed to simulate the combustion of a gasoline-ethanol blend with 45% (by mole) ethanol (E45) and a gasoline-butanol blend with 45% (by mole) n-butanol (B45) under the same operating conditions to study the effects of fuel composition and SOI timing on combustion phasing and soot emissions. The sooting propensity followed the trend: B45 > E20 > E45 at all SOI timings. Overall, it was observed that the autoignition propensity was primarily related to fuel chemistry. On the other hand, sooting propensity showed strong coupling with both fuel chemistry and physical properties, with greater impact of fuel physical properties at advanced SOI timings.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Virtual prototyping of liquid metal blanket performance in fusion pilot plant

Liquid metal blanket is a dominant design option for the next step fusion devices responsible for harvesting energy from fusion reaction, and simultaneously producing fuel for the same reaction through tritium breeding. Liquid metal blankets introduce additional complexity to the design due to fluid motion, fluid structure interaction, and magnetohydrodynamic (MHD) effects arising from the motion of the conducting fluid through the magnetic field. They are also directly affected by the plasma heat flux and neutronic fluence. PPPL is currently developing a virtual prototyping system for numerical analysis of the liquid metal blankets for future fusion devices. The system has a customized 3D computational fluid dynamics (CFD) code in its core, allowing MHD flow and conjugate heat transfer analysis in blankets fluids and solids. The code was successfully used before for dual coolant blanket analysis [A. Khodak et al., Fusion Eng. and Des. 137 (2018)]. Recently the same code was modified to allow verified simulation of MHD flows at high Hartmann numbers of several thousand typical for blanket applications. CFD code receives volumetric heat source distribution from the neutronic analysis based on MCNP code. In addition, direct tritium breeding simulation will be performed allowing optimization of the blanket performance. 2D axisymmetric version of neutronics code will be used for rapid optimization, with 3D version employed for detailed analysis. The surface heat distribution on the plasma facing wall will be defined by the software HEAT allowing 3D modeling of the heat flux based on the magnetic field distribution including gyro-orbit effects. Results of thermal analysis are imported into structural analysis code also included in the system. Finally, direct import of CAD geometry will be used for analyzing all components and as a result design option can be efficiently optimized.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗