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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

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗

Ripple-induced neoclassical toroidal viscous torque in Augmented-First Plasma operation phase in ITER

Abstract A systematic calculation is performed on the ripple-induced neoclassical toroidal viscous (NTV) torque for new ITER scenarios designed for the Augmented-First Plasma (A-FP) operation phase with the full tungsten wall, where the plasma-wall gap is varied in view of mitigating the impact of tungsten wall-plasma interactions. The torque calculation includes drift kinetic response of the plasma thermal and energetic particles to the n = 18 ( n is the toroidal harmonic number) ripple field. For the plasma scenario with ~45 cm plasma-wall gap at the outboard mid-plane and considering the corrected ripple level of 0.17% by the ferritic steel inserts, the computed net NTV torque acting on the plasma column is in the sub-Nm level. However, with decreasing the plasma-wall gap, the computed net NTV torque can reach a level comparable to that produced by the neutral-beam momentum injection in ITER. Ripple correction by ferritic inserts reduces the net torque by a factor of 3.3 for all the three A-FP scenarios considered. The n ω d = l ω b (with ω d and ω b being the toroidal precession and bounce frequencies of trapped particles, respectively, and l an integer number) type of resonance-enhancement of the NTV torque, due to thermal particles, is found to be weak in ITER despite high- n of 18. The same also holds for the ITER 10 MA steady state scenario from the D-T operation phase, where the aforementioned resonance associated with fusion-born alphas is also included. The ripple-induced NTV torque is well below that produced by the resonant magnetic perturbation applied for controlling the type-I edge-localized mode in ITER.

ITER↗

Overview of the MAST Upgrade physics programme: testing novel concepts at low aspect ratio to inform future devices

The research programme performed on the Mega Amp Spherical Tokamak (MAST) Upgrade experiment has made significant advances in developing the physics understanding of low aspect ratio tokamaks in support of the operation of ITER and design of fusion powerplants. High performance plasma scenarios have been developed to facilitate a broad programme of experiments, in which confinement is constrained by the presence of m/n = 2/1 modes that cause substantial losses of fast ions. The onset of these modes coincides with the q = 2 surface residing in a local minimum in the toroidal current density profile. The maximum electron temperature at the pedestal top, T e,ped is limited with gas fuelling to ∼350 eV to maintain regular ELMs; higher T e,ped results in a transition to a non-stationary ELM-free regime. The operational space of spherical tokamaks has been expanded into small and ELM-free regimes. Strong shaping of the last closed flux surface can induce a transition from large to small ELMs, and ELM suppression with resonant magnetic perturbations has been observed for the first time in a low aspect ratio tokamak. Negative triangularity shaping has induced a transition from ELMy H-mode to a high-performance L-mode regime for the first time in a low aspect ratio tokamak. In studies of fast ion confinement, losses of fast particles due to Global Alfvén Eigenmodes have been identified. Interactions between fast ions generated by off-axis neutral beam injection and thermal neutrals can result in significant losses of fast ions. Experiments with on- and off-axis neutral beam injection exhibit a flux pumping mechanism, where the central safety factor is held to ∼1 in the absence of sawteeth. In studies of pedestal physics, it has been found that elevated main chamber neutral pressures result in an increase in the electron density and reduction in the temperature at the pedestal top. Advances in understanding plasma exhaust include the integration of a high-performance plasma core with detached outer divertors in the X-point target configuration. A newly commissioned lower divertor cryopump reduces the lower divertor neutral pressure by up to 50%, with minimal effect on the main chamber or upper divertor. New measurements and SOLPS-ITER simulations emphasise the importance of plasma–neutral interactions on divertor detachment in the conditions accessible in experiments. Real-time control of the ionisation front location in both divertor chambers independently has been demonstrated in double null experiments, enabled by the tightly baffled divertor chambers.

MAST Upgrade↗

Large Format Composite Additive Manufacturing for Low-Head Hydropower

Hydropower with a small elevation change from inlet to outlet, known as “low-head” hydropower, is a relatively untapped resource for reliable green power generation. One major barrier to entry is the cost of the components needed to generate the power. Each installation site is unique, with various head levels, flow rates, and other unique site characteristics that drive up the cost of development and installation. As a result, custom-made components are necessary because the sites are intrinsically inefficient. However, customized parts are generally more expensive to manufacture than ready-made parts. Often times, the cost of custom-made components is so high that the low-head hydropower installation becomes non-viable. Additive manufacturing offers the ability to make custom components, ideal for one-off applications, at low costs that are well suited for the needs of low-head hydropower. Indirect additive manufacturing, such as making tools or dies rather than end use components, can also be used to make low-cost composite tooling as needed for these custom applications. This paper explores the use of additive manufacturing, both directly and indirectly, to produce the components of a turbine system for a low-head hydropower site. The parts were designed to form a unique modular system, which saves time for future designs and iterations. The system has operated for more than three years without failure at a test site in Wisconsin, USA. This work serves as a basis for future application of AM to low-head systems, in which the modular components can be customized for each unique hydropower installation.

36 MATERIALS SCIENCE↗

Advances in genome-scale metabolic models of industrially important fungi

Many fungal species have been used in industrial production for biofuels and bioproducts. Developing strains with better performance in biomanufacturing requires systematic understanding of cellular metabolism. Genome-scale metabolic models (GEMs) offer a comprehensive view of interconnected pathways and a mathematical framework for downstream analysis. Recently, GEMs have been developed or updated in several industrially important fungi. Some of them incorporate enzyme constraints, enabling improved predictions of cell states and proteome allocation. In this report we provide an overview of these newly developed GEMs and computational methods that facilitate construction of enzyme-constrained GEMs and utilize flux predictions from GEMs. Furthermore, we highlight the pivotal roles of these GEMs in iterative design-build-test- learn cycles, ultimately advancing the field of fungal biomanufacturing.

59 BASIC BIOLOGICAL SCIENCES↗

Stochastic AC optimal power flow: A data-driven approach

There is an emerging need for efficient solutions to stochastic AC Optimal Power Flow (AC-OPF) to ensure optimal and reliable grid operations in the presence of increasing demand and generation uncertainty. Herein this paper presents a highly scalable data-driven algorithm for stochastic AC-OPF that has extremely low sample requirement. The novelty behind the algorithm’s performance involves an iterative scenario design approach that merges information regarding constraint violations in the system with data-driven sparse regression. Compared to conventional methods with random scenario sampling, our approach is able to provide feasible operating points for realistic systems with much lower sample requirements. Furthermore, multiple sub-tasks in our approach can be easily paralleled and based on historical data to enhance its performance and application. We demonstrate the computational improvements of our approach through simulations on different test cases in the IEEE PES PGLib-OPF benchmark library.

42 ENGINEERING↗

Reduced-order CFD modeling of cryogenic hydrogen isotope extrusion for pellet fueling

This study presents a reduced-order model (ROM) for computational fluid dynamics (CFD) simulations of cryogenic hydrogen isotope extrusions, focusing on protium (H₂) and deuterium (D₂) piston extruders. Using a 2D axisymmetric ROM in ANSYS-Polyflow, significant computational savings were achieved (runtime reduced from 9∼24 h to 3∼5 min), with extrusion force discrepancies between the 2D ROM and 3D models being on the order of 1%. Parametric studies identified optimal cutoff shear rates in the viscosity model (0.01/s for H₂ and 0.001/s for D₂), providing recommendations for future simulations. Finally, a comprehensive comparison of ROM results with experimental data was performed across varying geometries, cryogenic materials, temperatures, extrusion lengths, and piston velocities. Predictions at low extrusion temperatures met the objective of providing quick and efficient solutions with an acceptable extrusion force error of approximately 10% or less, validating the effectiveness of the 2D ROM approach. However, at high temperatures closer to the triple point, extrusion force error grows, which necessitates developing an improved model that accounts for temperature effects, e.g. melting. Nevertheless, the findings still represent a significant improvement in efficiency of CFD modeling of cryogenic hydrogenic extrusion. The ROM framework can also be extended to tritium (T2) and screw extruders, which will ultimately provide a fast and effective tool for optimizing pellet injector design for ITER and future reactor systems.

Fan, Joy [ORNL] (ORCID:0000000229751735)↗

Creep anisotropy modeling and uncertainty quantification of an additively manufactured Ni-based superalloy

The advantages offered by additive manufacturing over traditional processes has driven a great deal of industrial and academic interest in recent years. However, the process is relatively new and requires additional investigation to become sufficiently mature for wide scale industrial adoption. Electron beam melting powder bed fusion is one technology that has shown promise for fabricating high temperature resistant materials such as nickel based superalloys. The resulting microstructures typically exhibit a strong fiber texture in the build direction giving rise to anisotropic time-dependent deformation behavior. In order to accelerate the qualification of these materials for industrial adoption accurate numerical models are needed for simulating their behavior. In this work a crystal plasticity model including non-Schmid effects is presented for capturing creep anisotropy observed in additively manufactured IN738LC. The model is calibrated via a probabilistic framework where model parameters are treated as random variables. An iterative sequential design strategy is utilized to efficiently identify the probability density of the unknown model parameters. As a case study the model is utilized to investigate the behavior of randomly oriented equiaxed grain clusters sometimes observed embedded in the additively manufactured columnar structure. A synthetic realization is simulated and uncertainty is propagated through to the full-field response. Results indicate that these features are the source of significant creep relaxation and strain accumulation which partially explains observed grain boundary decohesion at these locations.

36 MATERIALS SCIENCE↗

Optimal Control of the Energy-Saving Hybrid Hydraulic-Electric Architecture (HHEA) for Off-Highway Mobile Machines

Most off-highway constructions and agriculture equipment use hydraulics, which has unmatched power density, for power transmission and throttling as a means for control. A novel hybrid hydraulic-electric architecture (HHEA) has recently been proposed to improve efficiency for high-power machines that would have been cost-prohibitive to electrify directly. HHEA uses a set of common pressure rails (CPRs) to transmit the majority of power hydraulically and small electric motor drives to modulate that power and to achieve precise control. This article proposes a computationally efficient Lagrange multiplier method (LMM) for computing the optimal sequence of pressure rail selections to minimize energy use. This is needed to evaluate HHEA's energy-saving potential and for iterative architecture design and sizing. An interesting complication is that the cost function is not fully defined until the candidate control sequence is fully specified. This issue is dealt with by decomposing the original problem into a set of sub-problems with additional constraints that can be solved efficiently. Computational effort can be further reduced if actuators are optimized individually instead of together. However, additional steps are required to prevent the constraint functions from becoming discontinuous with respect to the Lagrange multipliers, which is necessary for meeting the constraints. Lastly, a case study of a construction machine demonstrates the efficacy of the method and shows that the HHEA reduces energy consumption by 68%-73% compared to the baseline load-sensing architecture.

Lagrange multiplier↗

Repair and Resource Scheduling in Unbalanced Distribution Systems Using Neighborhood Search

—This paper proposes an optimization strategy to assist utility operators to recover power distribution systems after large outages. Specifically, a mixed-integer linear programming (MILP) model is developed for co-optimizing crews, resources, and network operations. The MILP model coordinates damage isolation, network reconfiguration, distributed generator re-dispatch, and crew/resource logistics. In addition, a framework for integrating different types of photovoltaic (PV) systems in the restoration process is developed. We consider two different types of crews, namely, line crews for damage repair and tree crews for obstacle removal. We also model the repair resource logistic constraints. Furthermore, a new algorithm is developed for solving the distribution system repair and restoration problem (DSRRP). The algorithm starts by solving DSRRP using an assignmentbased method, then a neighborhood search method is designed to iteratively improve the solution. The proposed method is validated on modified IEEE 123- and 8500-bus distribution test systems.

Outage management↗

Navigating the Dynamic Noise Landscape of Variational Quantum Algorithms with QISMET

In the Noisy Intermediate Scale Quantum (NISQ) era, the dynamic nature of quantum systems causes noise sources to constantly vary over time. Transient errors from the dynamic NISQ noise landscape are challenging to comprehend and are especially detrimental to classes of applications that are iterative and/or long-running, and therefore their timely mitigation is important for quantum advantage in real-world applications. The most popular examples of iterative long-running quantum applications are variational quantum algorithms (VQAs). Iteratively, VQA’s classical optimizer evaluates circuit candidates on an objective function and picks the best circuits towards achieving the application’s target. Noise fluctuation can cause a significant transient impact on the objective function estimation of the VQA iterations’ tuning candidates. This can severely affect VQA tuning and, by extension, its accuracy and convergence. Furthermore, this paper proposes QISMET: Quantum Iteration Skipping to Mitigate Error Transients, to navigate the dynamic noise landscape of VQAs. QISMET actively avoids instances of high fluctuating noise which are predicted to have a significant transient error impact on specific VQA iterations. To achieve this, QISMET estimates transient error in VQA iterations and designs a controller to keep the VQA tuning faithful to the transient-free scenario. By doing so, QISMET efficiently mitigates a large portion of the transient noise impact on VQAs and is able to improve the fidelity by 1.3x-3x over a traditional VQA baseline, with 1.6-2.4x improvement over alternative approaches, across different applications and machines.

Ravi, Gokul Subramanian↗

Progress Report for W911NF-23-1-0323: Development of Scalable Three-Dimensional Ion Traps for Quantum Information Processing

Trapped atomic ions are a promising platform for scalable quantum information processing. They lead in many key metrics such as single and two qubit gate fidelities, as well as quantum volume. We recently realized novel 3D ion traps with a high resolution 3D-printing process. The traps combine the scalability potential of surface chip traps with the superior trap performance of macroscopic 3D ion traps. Like photolithography, 3D-printing is a digitally defined process and hence allows for rapid iteration between design and fabrication. In contrast to photolithography, it also allows for fully defined 3D structures and, thus, is an ideal process to develop large, well-defined trap arrays with complex 3D electrode structures. Our current goal is to implement key procedures and perform critical measurements that justify incorporation of 3D-printed traps into large-scale quantum computing efforts. En route, we recently realized trapping in horizontal traps that are operating at cryogenic temperatures.

74 ATOMIC AND MOLECULAR PHYSICS↗

LITE-SM: A Light Sheet Illuminator Compatible with Super Resolution and Single Molecule Imaging

The LITE-SM (hereinafter referred to as the Tilt-SM) is a light sheet illumination system purpose-built for single molecule (SM) imaging. SM imaging is a fluorescence imaging technique where individual molecules can be tracked in living cells/tissues in real time allowing for unprecedented insights into the intracellular dynamics of these molecules. The innovative all-mirror optical design greatly reduces/eliminates the aberrations that plague lens-based designs. This iteration of the Tilt-SM has significantly better optical performance then its predecessor with over 10x increase in optical power at the sample, allowing for the use of much smaller and more cost-effective lasers then the original Phase 1 system. Excellent STORM imaging as well as SM tracking has been achieved, satisfying the key objectives of this study.

59 BASIC BIOLOGICAL SCIENCES↗

Equity-Centered Engagement Through Climate Resilience Policy in Massachusetts

Communities who experience disproportionate climate change impacts tend to be excluded from resilience planning (Vale, 2014). Those efforts typically follow top-down processes within established governance practices that are inaccessible to marginalized folks and reinforce inequalities (Malloy & Ashcraft, 2020; Adger, 2003). Such participatory planning processes may offer the public little opportunity to influence the process itself or the outcomes (Smith & McDonough, 2001). They might ignore important public values or alternative ways of knowing which can be critical assets in resilience (Few et al., 2007). Designing communities for climate action and resilience means creating opportunities for everyone to meaningfully shape those decisions and experience related benefits. Having the opportunity to shape one’s community is necessary for human flourishing (Allen, 2016). Resilience planning that shifts power into communities and focuses on social vulnerability can affect how people survive and thrive in a climate changed world. The Massachusetts Municipal Vulnerability Preparedness (MVP) 2.0 program is an attempt to change the status quo in resilience planning by bringing new voices into decision-making power, recognizing their labor, addressing root causes of vulnerability, and investing in social infrastructure. It aspires to build capacity for equity-focused community engagement within teams of municipal staff and community liaisons, and ultimately build social capital and community cohesion. My mixed methods research investigates implementation of this state grant program in several western Massachusetts towns. I am using document review, participant observation, and interviews to understand the MVP 2.0 process as written, how different towns navigate it, and how individuals make sense of their experiences in it. I seek to understand how those experiences explain relationships between engagement approaches, mediating factors, and process outcomes. I am interested in the conditions that allow for community empowerment and how a model like MVP 2.0 can shift conditions that hold systems in place. In a practical sense, our findings will help municipalities reflect on their work during MVP 2.0 and plan for future community engagement. They may be informative for designing future iterations of the MVP program and for other municipalities, offices of community engagement, and practitioners. The findings will also contribute to the participation, resilience, and climate justice literatures, by adding perspectives on equity-centered resilience and community engagement approaches in smaller towns and rural settings. References: Adger, W. N. (2003). Social capital, collective action, and adaptation to climate change. Economic Geography, 79, 387-404. Allen, D. (2016). Toward a connected society. Our compelling interests: The value of diversity for democracy and a prosperous society, 71-105. Few, R., Brown, K., & Tompkins, E. L. (2007). Public participation and climate change adaptation: avoiding the illusion of inclusion. Climate Policy, 7(1), 46–59. Malloy, J. T., & Ashcraft, C. M. (2020). A framework for implementing socially just climate adaptation. Climatic Change, 160(1), 1–14. Smith, P. D., & McDonough, M. H. (2001). Beyond public participation: Fairness in natural resource decision making. Society & natural resources, 14(3), 239-249. Vale, L. J. (2014). The politics of resilient cities: whose resilience and whose city? Building Research & Information, 42(2), 191–201.

Callaham, Shannon↗

Equity-Centered Engagement Through Climate Resilience Policy in Massachusetts

Resilience efforts tend to reinforce injustices. Communities who experience disproportionate climate impacts are often excluded from resilience planning, and those plans do not typically address root causes of social vulnerability. More transformational approaches to resilience would shift decision-making power into communities and affect how people survive and thrive in a climate changing world. The Massachusetts Municipal Vulnerability Preparedness (MVP) 2.0 program is an attempt to change the status quo in resilience planning by bringing new voices into decision-making power, recognizing their labor, addressing root causes of vulnerability, and investing in social infrastructure. It aims to build capacity for equity-focused community engagement within teams of municipal staff and community liaisons, and ultimately build community cohesion. My mixed methods research investigates implementation of this state grant program in several Massachusetts towns. I am using document review, participant observation, and interviews to understand the MVP 2.0 process as written, how different municipalities navigate it, and how individuals make sense of their experiences in it. I seek to understand how those experiences explain relationships between engagement approaches, mediating factors, and process outcomes. I am interested in the conditions that allow for community empowerment and how a model like MVP 2.0 can shift conditions that hold systems in place. In a practical sense, my empirical results will help municipalities reflect on their work during MVP 2.0 and plan for future community engagement. They may be informative for designing future iterations of the MVP program and for other municipalities, offices of community engagement, and practitioners. The findings will also contribute to the participation, resilience, and climate justice literatures, by adding perspectives on equity-centered resilience and community engagement approaches in smaller towns and rural settings.

Callaham, Shannon↗

Equity-Centered Engagement Through Climate Resilience Policy in Massachusetts

Communities who experience disproportionate climate change impacts tend to be excluded from resilience planning. Those efforts typically follow top-down processes within established governance practices that are inaccessible to marginalized folks and reinforce inequalities. Regenerating the commons includes creating opportunities for everyone to meaningfully shape community resilience decisions and experience related benefits. Resilience planning that shifts power into communities and focuses on social vulnerability can affect how people survive and thrive in a climate changed world. The Massachusetts Municipal Vulnerability Preparedness (MVP) 2.0 program is an attempt to change the status quo in resilience planning by bringing new voices into decision-making power, recognizing their labor, addressing root causes of vulnerability, and investing in social infrastructure. It aspires to build capacity for equity-focused community engagement within teams of municipal staff and community liaisons, and ultimately build social capital and community cohesion. My research investigates implementation of this state grant program in several western Massachusetts towns. I am using document review, participant observation, and interviews to understand the MVP 2.0 process as written, how different towns navigate it, and how individuals make sense of their experiences in it. I seek to understand how those experiences explain relationships between engagement approaches, mediating factors, and process outcomes. I am interested in the conditions that allow for community empowerment and how a model like MVP 2.0 can shift conditions that hold systems in place. In a practical sense, our findings will help municipalities reflect on their work during MVP 2.0 and plan for future community engagement. They may be informative for designing future iterations of the MVP program and for other municipalities or offices of community engagement. The findings will also contribute to the participation, resilience, and climate justice literatures, by adding perspectives on equity-centered resilience and community engagement approaches in smaller towns and rural settings.

Callaham, Shannon↗

Studies of leading-edge thrust phenomena

A study of practical limitations on achievement of theoretical leading-edge thrust has been made and an empirical method for estimation of attainable thrust has been developed. The method is based on a theoretical analysis of a set of two-dimensional airfoils to define thrust dependence on airfoil geometric characteristics and arbitrarily defined limiting pressures, an examination of two-dimensional airfoil experimental data to provide an estimate of limiting pressure dependence on local Mach number and Reynolds number, and employment of simple sweep theory to adapt the method to three-dimensional wings. Because the method takes into account the spanwise variation of airfoil section characteristics, an opportunity is afforded for design by iteration to maximize the attainable thrust and the attendant performance benefits. The applicability of the method was demonstrated by comparisons of theoretical and experimental aerodynamic characteristics for a series of wing-body configurations. Generally, good predictions of the attainable thrust and its influence on lift and drag characteristics were obtained over a range of Mach numbers from 0.24 to 2.0.

Carlson, H. W.↗

Spacecraft loads methodology - Transient vs. shock spectra method

The methodology for the establishment of spacecraft loads is strongly influenced by project constraints which include the cost, schedule and allowable weight. The most rigorous approach is the transient loads analysis which requires a composite mathematical model of the spacecraft and launch vehicle. The structural member loads for the entire composite structure are computed by applying the forcing functions, which represent various dynamic environments during the mission, to the composite model. Although this method ideally leads to a lightweight design, it is costly and time consuming due to complex interfaces involving many organizations. To reduce complexity and cost a shock spectra method has been used to design spacecraft structures. This method utilizes envelopes of shock spectra of launch vehicle accelerations obtained from analysis and/or flight measurements. Since only limited information on the launch vehicle model is involved in this process the design loads iteration cycle can be rapidly performed within the payload organization. In the present paper, these two methods will be evaluated by comparing the loads for several spacecraft. Flight measured loads will also be used in the evaluation.

Chen, J. C.↗