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DOE OSTI2024

Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D) (Final Technical Report)

As the U.S clean energy transition hinges on the growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements to enable robust and cost-competitive wind turbines. The race to build larger and taller turbines rated 10 megawatts (MW) and beyond, has intensified pressure on OEMs in terms of logistics of handling and transporting large wind components, securing critical raw material as well as scaling up necessary domestic production infrastructure to meet the demand. There is increased interest in building lightweight, more efficient, and high-power dense drivetrains that will ease the burden on installation, minimize the raw material demand, increasing domestic sourceability. Despite good efficiency and reliability, existing drivetrain technologies such as direct-drive permanent magnet generators are heavy (> 300 tons), expensive, and often rely on large quantities of rare-earth permanent magnets (PMs), steel and copper.

17 WIND ENERGY↗

NASA NTRS1994

Applying Analog Integrated Circuits for Hero Protection

One of the most efficient methods for protecting electro-explosive devices (EED's) from HERO and ESD is to shield the EED in a conducting shell (Faraday cage). Electrical energy is transferred to the bridge by means of a magnetic coupling which passes through a portion of the conducting shell that is made from a magnetically permeable but electrically conducting material. This technique was perfected by ML Aviation, a U.K. company, in the early 80's, and was called a Radio Frequency Attenuation Connector (RFAC). It is now in wide use in the U.K. Previously, the disadvantage of RFAC over more conventional methods was its relatively high cost, largely driven by a thick film hybrid circuit used to switch the primary of the transformer. Recently, through a licensing agreement, this technology has been transferred to the U.S. and significant cost reductions and performance improvements have been achieved by the introduction of analog integrated circuits. An integrated circuit performs the following functions: (1) Chops the DC input to a signal suitable for driving the primary of the transformer; (2) Verifies the input voltage is above a threshold; (3) Verifies the input voltage is valid for a pre set time before enabling the device; (4) Provides thermal protection of the circuit; and (5) Provides an external input for independent logic level enabling of the power transfer mechanism. This paper describes the new RFAC product and its applications.

Kenneth E Willis↗

NASA NTRS2015

Standardized Modular Power Interfaces for Future Space Explorations Missions

Earlier studies show that future human explorations missions are composed of multi-vehicle assemblies with interconnected electric power systems. Some vehicles are often intended to serve as flexible multi-purpose or multi-mission platforms. This drives the need for power architectures that can be reconfigured to support this level of flexibility. Power system developmental costs can be reduced, program wide, by utilizing a common set of modular building blocks. Further, there are mission operational and logistics cost benefits of using a common set of modular spares. These benefits are the goals of the Advanced Exploration Systems (AES) Modular Power System (AMPS) project. A common set of modular blocks requires a substantial level of standardization in terms of the Electrical, Data System, and Mechanical interfaces. The AMPS project is developing a set of proposed interface standards that will provide useful guidance for modular hardware developers but not needlessly constrain technology options, or limit future growth in capability. In 2015 the AMPS project focused on standardizing the interfaces between the elements of spacecraft power distribution and energy storage. The development of the modular power standard starts with establishing mission assumptions and ground rules to define design application space. The standards are defined in terms of AMPS objectives including Commonality, Reliability-Availability, Flexibility-Configurability and Supportability-Reusability. The proposed standards are aimed at assembly and sub-assembly level building blocks. AMPS plans to adopt existing standards for spacecraft command and data, software, network interfaces, and electrical power interfaces where applicable. Other standards including structural encapsulation, heat transfer, and fluid transfer, are governed by launch and spacecraft environments and bound by practical limitations of weight and volume. Developing these mechanical interface standards is more difficult but an essential part of defining physical building blocks of modular power. This presentation describes the AMPS projects progress towards standardized modular power interfaces.

Spacecraft Power↗

DOE OSTI2020

Automotive fuel cell stack and system efficiency and fuel consumption based on vehicle testing on a chassis dynamometer at minus 18 °C to positive 35 °C temperatures

In this work we present an in-depth laboratory technology assessment of a 2016 Toyota Mirai Fuel Cell (FC) vehicle based on chassis dynamometer testing. The 114.6 kW FC stack has a high dynamic response, which makes this powertrain a FC-dominant hybrid electric vehicle. The measured peak efficiency is 66.0% FC stack and 63.7% FC system with an idle hydrogen flow rate of 4.39 g/hr. The high FC system efficiencies at low loads match typical vehicle power spectrums, resulting in a high average vehicle efficiency of 62% compared to 45% and 23% for a hybrid electric vehicle and a conventional vehicle, respectively. An energy breakdown accounts for the FC stack losses, FC system losses, air compressor loads, and heater loads for different drive cycles and different thermal conditions. The cold-start North American city drive cycle (UDDS) energy consumption values are, respectively, 758, 581, 226, and 321 Wh/km at ambient conditions of -18 degrees C, -7 degrees C, -25 degrees C and 35 degrees C with 850 W/m 2 of solar loading. The FC system shutdown and startup processes at temperatures below the freezing point contribute to the increased hydrogen consumption. Additionally, the raw test data files are available for download, thus providing the research community with a public reference data on a modern production automotive FC system.

08 HYDROGEN↗

NASA NTRS2010

NASA Tech Briefs, May 2010

Topics covered include: Instrument for Analysis of Greenland's Glacier Mills Cryogenic Moisture Apparatus; A Transportable Gravity Gradiometer Based on Atom Interferometry; Three Methods of Detection of Hydrazines; Crossed, Small-Deflection Energy Analyzer for Wind/Temperature Spectrometer; Wavefront Correction for Large, Flexible Antenna Reflector; Novel Micro Strip-to-Waveguide Feed Employing a Double-Y Junction; Thin-Film Ferro Electric-Coupled Microstripline Phase Shifters With Reduced Device Hysteresis; Two-Stage, 90-GHz, Low-Noise Amplifier; A 311-GHz Fundamental Oscillator Using InP HBT Technology; FPGA Coprocessor Design for an Onboard Multi-Angle Spectro-Polarimetric Imager; Serrating Nozzle Surfaces for Complete Transfer of Droplets; Turbomolecular Pumps for Holding Gases in Open Containers; Triaxial Swirl Injector Element for Liquid-Fueled Engines; Integrated Budget Office Toolbox; PLOT3D Export Tool for Tecplot; Math Description Engine Software Development Kit; Astronaut Office Scheduling System Software; ISS Solar Array Management; Probabilistic Structural Analysis Program; SPOT Program; Integrated Hybrid System Architecture for Risk Analysis; System for Packaging Planetary Samples for Return to Earth; Offset Compound Gear Drive; Low-Dead-Volume Inlet for Vacuum Chamber; Simple Check Valves for Microfluidic Devices; A Capillary-Based Static Phase Separator for Highly Variable Wetting Conditions; Gimballing Spacecraft Thruster; Finned Carbon-Carbon Heat Pipe with Potassium Working Fluid; Lightweight Heat Pipes Made from Magnesium; Ceramic Rail-Race Ball Bearings; Improved OTEC System for a Submarine Robot; Reflector Surface Error Compensation in Dual-Reflector Antennas; Enriched Storable Oxidizers for Rocket Engines; Planar Submillimeter-Wave Mixer Technology with Integrated Antenna; Widely Tunable Mode-Hop-Free External-Cavity Quantum Cascade Laser; Non-Geiger-Mode Single-Photon Avalanche Detector with Low Excess Noise; Using Whispering-Gallery-Mode Resonators for Refractometry; RF Device for Acquiring Images of the Human Body; Reactive Collision Avoidance Algorithm; Fast Solution in Sparse LDA for Binary Classification; Modeling Common-Sense Decisions in Artificial Intelligence; Graph-Based Path-Planning for Titan Balloons; Nanolaminate Membranes as Cylindrical Telescope Reflectors; Air-Sea Spray Airborne Radar Profiler Characterizes Energy Fluxes in Hurricanes; Large Telescope Segmented Primary Mirror Alignment; and Simplified Night Sky Display System.

Source record↗

DOE OSTI2023

Probing liquid/liquid interfaces at and away from equilibrium using vibrational sum frequency generation

The self-assembly and transport of species at oil/aqueous interfaces represent key mechanistic steps in processes spanning from liquid extraction to soft-matter neuromorphic electrical devices. While technologically and fundamentally important, there is a notable lack of chemical understanding regarding these buried interfaces due to challenges in differentiating species located at the surface from the nearby bulk phases. In this work, we will describe some of the challenges in probing chemistry at these liquid/liquid interfaces and detail the approaches we have developed using vibrational sum frequency generation to enable studies of these complex interfaces at and away from equilibrium. From these spectroscopic developments, new insight into solvation, ion pairing, aggregation, complexation, and transport will be discussed in the context of solvent extraction chemistry. Notably, we show how the presence of both oil and aqueous phases provides an environment to drive fundamentally different phenomena from what is observed at model air/aqueous interfaces. This difference arises from key differences in solvation and bulk populations that feedback onto the surface to drive emergent and often functional molecular assemblies.

Doughty, Benjamin L↗

NASA NTRS1994

The future of time and frequency dissemination

I will try to extrapolate the changes in the dissemination of time and frequency information that have taken place during the last 25 years to predict the future developments both in the methods of disseminating time and frequency and in the kinds of customers we will be asked to serve. Two important developments are likely to play pivotal roles in driving the evolution of dissemination. The first is the commercial availability of very high quality clocks -- devices whose performance may eventually rival that of the current generation of primary frequency standards. The widespread use of these devices may blur the traditional distinction between client and server, and may replace it with a more symmetrical interchange of data among peers. The second is the increasing demand for digital time and frequency information driven by the increasing sophistication of everything from traffic lights to electric power meters. The needs of these individual users may not tax the state of the art of primary frequency standards in principle, but their large numbers and wide geographical distribution present a technological challenge that is difficult to meet at a reasonable price using existing methods. Some of these problems may be solved (or at least addressed) using developments in communications and consumer electronics such as the increasing use of fiber-optic telephone circuits and the increasing bandwidth and sophistication of the cable network used to transmit television pictures. To be useful, these advances in hardware must stimulate parallel advances in software algorithms and methods. These advances are more difficult to predict with great confidence, but the developments of the last few years will be examined to provide some indications of the future.

Levine, Judah↗

NASA NTRS2014

Innovative Escapement-Based Mechanism for Micro-Antenna Boom Deployment

This paper presents the prototype of a tubular boom antenna developed for the Polish BRITE-PL satellite by the Space Research Center of the Polish Academy of Sciences (CBK PAN). What is unique about our work is that we developed an original type of the tubular boom antenna deployment mechanism that can be used widely as a basic solution for compact electrical antennas, booms deploying sensitive instruments, ultra-light planetary manipulators etc. The invented electromagnetic driving unit provides a dual complementary action - it adds extra energy to the driving spring, making the system more reliable, and at the same time it moderates the deployment speed acting as a kind of damper. That distinguishing feature predetermines the mechanism to be applied wherever the dynamic nature of a spring drive introducing dangerous vibrations and inducing severe local stress in the structure needs to be mitigated. Moreover, the paper reveals a product unique in Europe - a miniature beryllium bronze tubular boom free of geometry and strain defects, which is essential for stiffness and fatigue resistance. Both the deployment mechanism and the technology of tubular boom manufacturing are protected by patent rights.

Tokarz, Marta↗

DOE OSTI2022

Decarbonizing Medium & Heavy-Duty On-Road Vehicles

We analyze the decarbonization potential of medium and heavy-duty vehicles (MHDVs) across multiple vehicle classes and market segments. We evaluate the timeframe in which zero-emission vehicles (ZEVs) could achieve cost parity with conventional diesel vehicles and the implications for energy and emissions. Our results show that ZEVs can achieve cost parity with conventional vehicles by 2035 across the majority of vehicle classes and market segments. Emissions reductions range from 27% to 77% by 2050 relative to 2019 across multiple fuel cost and technology progress sensitivities. Multiple technology pathways are viable for decarbonization, including battery-electric vehicles and hydrogen fuel cell electric vehicles. This presentation is based on previous work published by NREL: Ledna, C., Muratori, M., Yip, A., Jadun, P., and Hoehne, C. 2022. Decarbonizing Medium & Heavy-Duty On-Road Vehicles: Zero-Emission Vehicles Cost Analysis. National Renewable Energy Laboratory, https://www.nrel.gov/docs/fy22osti/82081.pdf.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Photoexcitation of Fe 3 O Nodes in MOF Drives Water Oxidation at pH=1 When Ru Catalyst Is Present

Abstract Artificial photosynthesis strives to convert the energy of sunlight into sustainable, eco‐friendly solar fuels. However, systems with light‐driven water oxidation reaction (WOR) at pH=1 are rare. Broadly used [Ru(bpy) 3 ] 2+ (bpy=2,2’‐bipyridine) photosensitizer has a fixed +1.23 V potential which is insufficient to drive most water oxidation catalysts (WOCs) in acid, while Fe 2 O 3 , featuring the highly oxidizing holes, is not stable at low pH. Here, the key examples of Fe‐based metal–organic framework (MOF) water oxidation photoelectrocatalysts active at pH=1 are presented. Fe‐MIL‐126 and Fe MOF‐dcbpy structures were formed with 4,4’‐biphenyl dicarboxylate (bpdc), 2,2’‐bipyridine‐5,5’‐dicarboxylate (dcbpy) linkers and their mixtures. Presence of dcbpy linkers allows integration of metal‐based catalysts via coordination to 2,2’‐bipyridine fragments. Fe‐based MOFs were doped with Ru‐based precursors to achieve highly active MOFs bearing [Ru(bpy)(dcbpy)(H 2 O) 2 ] 2+ WOC. Materials were analyzed with X‐ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infra‐red (FTIR) spectroscopy, resonance Raman, X‐ray absorption spectroscopy, fs optical pump‐probe, electron paramagnetic resonance (EPR), diffuse reflectance and electric conductivity measurements and were modeled by band structure calculations. It is shown that under reaction conditions, Fe III and Ru III oxidation states are present, indicating rate‐limiting electron transfer in MOF. Fe 3 O nodes emerge as photosensitizers able to drive prolonged O 2 evolution in acid. Further developments are possible via MOF's linker modification for enhanced light absorption, electrical conductivity, reduced MOF solubility in acid, Ru‐WOC modification for faster WOC catalysis, or Ru‐WOC substitution to 3d metal‐based systems. The findings give further insight for development of light‐driven water splitting systems based on Earth‐abundant metals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Exciton Superposition across Moiré States in a Semiconducting Moiré Superlattice

Moiré superlattices of semiconducting transition metal dichalcogenides enable unprecedented spatial control of electron wavefunctions, leading to emerging quantum states. The breaking of translational symmetry further introduces a new degree of freedom: high symmetry moiré sites of energy minima behaving as spatially separated quantum dots. We demonstrate the superposition between two moiré sites by constructing a trilayer WSe 2 /monolayer WS 2 moiré heterojunction. The two moiré sites in the first layer WSe 2 interfacing WS 2 allow the formation of two different interlayer excitons, with the hole residing in either moiré site of the first layer WSe 2 and the electron in the third layer WSe 2 . An electric field can drive the hybridization of either of the interlayer excitons with the intralayer excitons in the third WSe 2 layer, realizing the continuous tuning of interlayer exciton hopping between two moiré sites and a superposition of the two interlayer excitons, distinctively different from the natural trilayer WSe 2 .

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2004

Performance of a Fuel-Cell-Powered, Small Electric Airplane Assessed

Rapidly emerging fuel-cell-power technologies may be used to launch a new revolution of electric propulsion systems for light aircraft. Future small electric airplanes using fuel cell technologies hold the promise of high reliability, low maintenance, low noise, and - with the exception of water vapor - zero emissions. An analytical feasibility and performance assessment was conducted by NASA Glenn Research Center's Airbreathing Systems Analysis Office of a fuel-cell-powered, propeller-driven, small electric airplane based on a model of the MCR-01 two-place kitplane (Dyn'Aero, Darois, France). This assessment was conducted in parallel with an ongoing effort by the Advanced Technology Products Corporation and the Foundation for Advancing Science and Technology Education. Their project - partially funded by a NASA grant - is to design, build, and fly the first manned, continuously propelled, nongliding electric airplane. In our study, an analytical performance model of a proton exchange membrane (PEM) fuel cell propulsion system was developed and applied to a notional, two-place light airplane modeled after the MCR-01 kitplane. The PEM fuel cell stack was fed pure hydrogen fuel and humidified ambient air via a small automotive centrifugal supercharger. The fuel cell performance models were based on chemical reaction analyses calibrated with published data from the fledgling U.S. automotive fuel cell industry. Electric propeller motors, rated at two shaft power levels in separate assessments, were used to directly drive a two-bladed, variable-pitch propeller. Fuel sources considered were compressed hydrogen gas and cryogenic liquid hydrogen. Both of these fuel sources provided pure, contaminant-free hydrogen for the PEM cells.

Berton, Jeffrey J.↗

NASA NTRS2014

Solid-State Thermionic Nuclear Power for Megawatt Propulsion, Planetary Surface and Commercial Power Project

Thermionic (TI) power conversion is a promising technology first investigated for power conversion in the 1960's, and of renewed interest due to modern advances in nanotechnology, MEMS, materials and manufacturing. Benefits include high conversion efficiency (20%), static operation with no moving parts and potential for high reliability, greatly reduced plant complexity, and the potential for reduced development costs. Thermionic emission, credited to Edison in 1880, forms the basis of vacuum tubes and much of 20th century electronics. Heat can be converted into electricity when electrons emitted from a hot surface are collected across a small gap. For example, two "small" (6 kWe) Thermionic Space Reactors were flown by the USSR in 1987-88 for ocean radar reconnaissance. Higher powered Nuclear-Thermionic power systems driving Electric Propulsion (Q-thruster, VASIMR, etc.) may offer the breakthrough necessary for human Mars missions of < 1 yr round trip. Power generation on Earth could benefit from simpler, moe economical nuclear plants, and "topping" of more fuel and emission efficient fossil-fuel plants.

George, Jeffrey↗

DOE OSTI2022

Autonomous Eco-Driving with Traffic Light and Lead Vehicle Constraints: An Application of Best Constrained Interpolation

Eco-Driving is a critical technology for improving automotive transportation efficiency. It is achieved by modifying the driving trajectory over a particular route to minimize required propulsion energy. Eco-Driving can be approached as an optimal control problem subject to driving constraints such as traffic lights and positions of other vehicles. Best interpolation in a strip is a problem in approximation theory and optimal control. The solution to this problem is a cubic spline. In this research, we demonstrate the connection between Eco-Driving and best interpolation in the strip. By exploiting this connection, we are able to generate optimal Eco-Driving trajectories that could be driven with an autonomous system. Using the simulation tool FASTSim, we can evaluate the trajectories using conventional, hybrid electric, and fully electric vehicle models. Our results quantify the energy efficiency improvements that can be achieved with the proposed approach.

Mahmoud, Yara Hazem↗

DOE OSTI2022

Autonomous Eco-Driving with Traffic Light and Lead Vehicle Constraints: An Application of Best Constrained Interpolation

Mahmoud, Yara Hazem↗

DOE OSTI2021

Topological Magnets: Functions Based on Berry Phase and Multipoles

Macroscopic responses of magnets are often governed by magnetization and, thus, have been restricted to ferromagnets. However, such responses are strikingly large in the newly developed topological magnets, breaking the conventional scaling with magnetization. Taking the recently discovered antiferromagnetic (AF) Weyl semimetals as a prime example, we highlight the two central ingredients driving the significant macroscopic responses: the Berry curvature enhanced because of nontrivial band topology in momentum space, and the cluster magnetic multipoles in real space. The combination of large Berry curvature and multipoles enables large macroscopic responses such as the anomalous Hall and Nernst effects, the magneto-optical effect, and the novel magnetic spin Hall effect in antiferromagnets with negligible net magnetization, but also allows us to manipulate these effects by electrical means. Furthermore, nodal-point and nodal-line semimetallic states in ferromagnets may provide the strongly enhanced Berry curvature near the Fermi energy, leading to large responses beyond the conventional magnetization scaling. These significant properties and functions of the topological magnets lay the foundation for future technological development such as spintronics and thermoelectric technology.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1998

Tunable Dielectric Materials and Devices for Broadband Wireless Communications

Wireless and satellite communications are a rapidly growing industries which are slated for explosive growth into emerging countries as well as countries with advanced economies. The dominant trend in wireless communication systems is towards broadband applications such as multimedia file transfer, video transmission and Internet access. These applications require much higher data transmission rates than those currently used for voice transmission applications. To achieve these higher data rates, substantially larger bandwidths and higher carrier frequencies are required. A key roadblock to implementing these systems at K-band (18-26.5 GHz) and Ka-band (26.5-40 GHz) is the need to develop hardware which meets the requirements for high data rate transmission in a cost effective manner. In this chapter, we report on the status of tunable dielectric thin films for devices, such as resonators, filters, phased array antennas, and tunable oscillators, which utilize nonlinear tuning in the control elements. Paraelectric materials such as Barium Strontium Titanate ((Ba, Sr)TiO3) have dielectric constants which can be tuned by varying the magnitude of the electric field across the material. Therefore, these materials can be used to control the frequency and/or phase response of various devices such as electronically steerable phased array antennas, oscillators, and filters. Currently, tunable dielectric devices are being developed for applications which require high tunability, low loss, and good RF power-handling capabilities at microwave and millimeter-wave frequencies. These properties are strongly impacted by film microstructure and device design, and considerable developmental work is still required. However, in the last several years enormous progress has occurred in this field, validating the potential of tunable dielectric technology for broadband wireless communication applications. In this chapter we summarize how film processing techniques, microwave test configurations, and prototype devices have combined to drive the field to its current stage of development.

Mueller, Carl H.↗

NASA NTRS1999

Electro-Statically Stricted Polymers (ESSP)

Miniature, lightweight, miser actuators that operate similar to biological muscles can be used to develop robotic devices with unmatched capabilities and impact many technology areas. Electroactive polymers (EAP) offer the potential to producing such actuators and their main attractive feature is their ability to induce relatively large bending or longitudinal strain. EAP actuators can change the paradigm about the complexity of robots, where robotic components such as motors, gears, bearings, and others can be eliminated with simple drive mechanisms. Generally, these materials produce a relatively low force and the applications that can be considered at the current state of the art are relatively limited. While improved material are being developed there is a need for methods to develop longitudinal actuators that can contract similar to muscles. In this study, the authors began investigating the electromechanical behavior of polymers in reaction to a complex configuration of electric fields. A computer model was used to simulate the electromechanical response. Efforts were made to develop both the material basis as well as the electromechanical modeling of the actuator.

Liu, C.↗