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NASA NTRSDate not supplied

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric surface imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method models. Data collection methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps on how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the pre-processing methods and results from Py_TIGIRS are provided and compared for Composite Test Article (CTA) 8.2B. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future development of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Sandwich structures↗

NASA NTRS2008

NASA Ares I Crew Launch Vehicle Upper Stage Overview

By incorporating rigorous engineering practices, innovative manufacturing processes and test techniques, a unique multi-center government/contractor partnership, and a clean-sheet design developed around the primary requirements for the International Space Station (ISS) and Lunar missions, the Upper Stage Element of NASA's Crew Launch Vehicle (CLV), the "Ares I," is a vital part of the Constellation Program's transportation system. Constellation's exploration missions will include Ares I and Ares V launch vehicles required to place crew and cargo in low-Earth orbit (LEO), crew and cargo transportation systems required for human space travel, and transportation systems and scientific equipment required for human exploration of the Moon and Mars. Early Ares I configurations will support ISS re-supply missions. A self-supporting cylindrical structure, the Ares I Upper Stage will be approximately 84' long and 18' in diameter. The Upper Stage Element is being designed for increased supportability and increased reliability to meet human-rating requirements imposed by NASA standards. The design also incorporates state-of-the-art materials, hardware, design, and integrated logistics planning, thus facilitating a supportable, reliable, and operable system. With NASA retiring the Space Shuttle fleet in 2010, the success of the Ares I Project is essential to America's continued leadership in space. The first Ares I test flight, called Ares I-X, is scheduled for 2009. Subsequent test flights will continue thereafter, with the first crewed flight of the Crew Exploration Vehicle (CEV), "Orion," planned for no later than 2015. Crew transportation to the ISS will follow within the same decade, and the first Lunar excursion is scheduled for the 2020 timeframe.

McArthur, J. Craig↗

NASA NTRS2008

NASA Ares I Crew Launch Vehicle Upper Stage Overview

By incorporating rigorous engineering practices, innovative manufacturing processes and test techniques, a unique multi-center government/contractor partnership, and a clean-sheet design developed around the primary requirements for the International Space Station (ISS) and Lunar missions, the Upper Stage Element of NASA's Crew Launch Vehicle (CLV), the "Ares I," is a vital part of the Constellation Program's transportation system. Constellation's exploration missions will include Ares I and Ares V launch vehicles required to place crew and cargo in low-Earth orbit (LEO), crew and cargo transportation systems required for human space travel, and transportation systems and scientific equipment required for human exploration of the Moon and Mars. Early Ares I configurations will support ISS re-supply missions. A self-supporting cylindrical structure, the Ares I Upper Stage will be approximately 84' long and 18' in diameter. The Upper Stage Element is being designed for increased supportability and increased reliability to meet human-rating requirements imposed by NASA standards. The design also incorporates state-of-the-art materials, hardware, design, and integrated logistics planning, thus facilitating a supportable, reliable, and operable system. With NASA retiring the Space Shuttle fleet in 2010, the success of the Ares I Project is essential to America's continued leadership in space. The first Ares I test flight, called Ares 1-X, is scheduled for 2009. Subsequent test flights will continue thereafter, with the first crewed flight of the Crew Exploration Vehicle (CEV), "Orion," planned for no later than 2015. Crew transportation to the ISS will follow within the same decade, and the first Lunar excursion is scheduled for the 2020 timeframe.

Davis, Daniel J.↗

NASA NTRSDate not supplied

Design and Analysis of Shape Memory Spring Tires for Martian and Lunar Rover Vehicles

Shape memory alloys (SMAs) have played an important role in various innovative engineering and medical applications, such as aerospace actuators, vibration damping devices, and coronary stents. In applications, shape memory alloys are commonly utilized in two fundamentally different ways: (i) making use of the superelasticity/ pseudoelasticity (SE/PE) phenomena, as in applications in biomedical engineering, and (ii) taking advantages of the shape memory effect (SME), as is used for actuators. Their ability to act in such vastly different capacities is mainly due to their unique capability to recover large amounts of deformation produced by either applied stresses or temperature changes. One recent emerging application in use of SMAs has been in the area of non-pneumatic tire designs for Martian or Lunar roving vehicles. These vehicles require tires that are capable of traversing rugged terrain while withstanding extreme temperatures and atmospheric conditions. Inspired by the flexible wire mesh tires used on three Lunar Roving Vehicle (LRV) missions to the Moon on Apollo 15, 16, and 17, a new compliant tire technology was developed by the NASA Glenn Research Center (GRC) and Goodyear Tire & Rubber, known as the Spring Tire. The Spring Tire consists of several hundred coiled springs woven into a flexible mesh and formed into the shape of a tire. Like the LRV wire mesh tires, the original Spring Tires were made from spring steel and were prone to permanent deformation when undergoing high localized loads. Later, a new iteration of this technology was invented, known as the ‘Superelastic Tire’. This new technology incorporated the use of superelastic SMA springs, which could effectively undergo approximately 30 times more reversible deformation than the steel spring. It also provided even greater durability and allowed for more flexibility in design, such as the use of other structural forms to reduce mass or increase load carrying capacity. Because of the unique nature of both the SMA material and the complex interactions between the springs, designing Spring Tires for a specific application requires extensive effort. Historically, design decisions have relied on full-scale empirical testing; however, this is very expensive and time consuming, especially when multiple iterations are needed. Therefore, developing a large-scale, robust, and predictive numerical model entailing complex spring interactions and the shape memory material behavior within a tire construct is the first essential step towards a successful design program. The current work focuses on implementation of the user-defined Shape Memory Alloy (SMA) model, otherwise known as SMA-GVIPs, in the Finite Element analysis (FEA) program ABAQUS for large-scale simulations of the GRC-developed Spring Tires made of SMA. The novelty of this work lies in the thorough, detail-oriented, and computationally efficient finite element analysis of full-scale SMA tires. A well-thought material characterization plan followed by model validation and a systemic sensitivity study on SMA tires has never been reported in the previous literature. The main objective of this study is to help the team improve and optimize the structural design of the SMA tires through in-depth numerical analysis and sensitivity studies. Various design variables (wire diameter, coil diameter, pitch, bead angle, and number of springs) were varied to study their influence on the global load-displacement response of the tire construct. A detailed investigation of the three-dimensional stress states was also carried out to enhance our understanding of the local changes as the tire goes through global deformation. It was concluded that a robust numerical model with a good predictive capability, together with a thoughtfully crafted sensitivity study can result in improved design iterations required to reach a desired tire performance while, significantly reducing manufacturing, labor and testing expenses. A summary of the Finite Element (FE) model construction will be presented together with a description of the user-defined SMA model, characterization process, experimental results, model validation, and numerical sensitivity study results.

shape memory alloys↗

DOE OSTI2023

Environmental and Economic Implications of Emerging Plastic Recycling Technologies

Recycling will play a crucial role in mitigating plastic pollution and promoting a circular economy for polymers. Quantitative analysis can help guide the optimization and implementation of these plastic management strategies, enabling increased circularity while minimizing costs, energy use, greenhouse gas emissions, and other environmental impacts. This talk will outline the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium's approach to analysis-guided plastic recycling research. Stringent process modelling, life cycle assessment, and techno-economic analysis are used to benchmark the technical feasibility, environmental impacts, and costs of chemical and biological recycling technologies in comparison to conventional fossil fuel-based plastic manufacturing. Across emerging recycling strategies, several key challenges become apparent - including plastic feedstock pretreatment requirements, high energy or chemical use, and recycled plastic yields and quality - highlighting opportunities for future innovation. Through this consistent and in-depth analysis approach, BOTTLE aims to provide the plastics community with key metrics and insights to drive plastic recycling innovation towards a more sustainable and circular economy.

circular economy↗

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2011

NASA Space Technology Draft Roadmap Area 13: Ground and Launch Systems Processing

This slide presentation reviews the technology development roadmap for the area of ground and launch systems processing. The scope of this technology area includes: (1) Assembly, integration, and processing of the launch vehicle, spacecraft, and payload hardware (2) Supply chain management (3) Transportation of hardware to the launch site (4) Transportation to and operations at the launch pad (5) Launch processing infrastructure and its ability to support future operations (6) Range, personnel, and facility safety capabilities (7) Launch and landing weather (8) Environmental impact mitigations for ground and launch operations (9) Launch control center operations and infrastructure (10) Mission integration and planning (11) Mission training for both ground and flight crew personnel (12) Mission control center operations and infrastructure (13) Telemetry and command processing and archiving (14) Recovery operations for flight crews, flight hardware, and returned samples. This technology roadmap also identifies ground, launch and mission technologies that will: (1) Dramatically transform future space operations, with significant improvement in life-cycle costs (2) Improve the quality of life on earth, while exploring in co-existence with the environment (3) Increase reliability and mission availability using low/zero maintenance materials and systems, comprehensive capabilities to ascertain and forecast system health/configuration, data integration, and the use of advanced/expert software systems (4) Enhance methods to assess safety and mission risk posture, which would allow for timely and better decision making. Several key technologies are identified, with a couple of slides devoted to one of these technologies (i.e., corrosion detection and prevention). Development of these technologies can enhance life on earth and have a major impact on how we can access space, eventually making routine commercial space access and improve building and manufacturing, and weather forecasting for example for the effect of these process improvements on our daily lives.

Clements, Greg↗

DOE OSTI2026

Cost estimation of balance of plant equipment scale up for proton exchange membrane water electrolyzer systems

Water electrolyzers that use electricity to split water into hydrogen and oxygen could be a key technology for increasing hydrogen supply to meet expanded and emerging market applications, although currently the capital costs of these electrolyzers are high. Here we examine cost reductions that might be achieved by scaling up proton exchange membrane (PEM) electrolyzer systems and leveraging economies of scale through balance of plant (BOP) components for system sizes between 1 MW and 1 GW. We estimate BOP equipment capital costs of about $\$$848/kW at 1 MW, potentially decreasing to $\$$87/kW at 1 GW (2022-dollar year basis) with most of the cost reduction happening as systems scale from 1 MW to 100 MW. We find that BOP subsystems hydrogen drying and water knockout benefited the most from economies-of-scale cost reductions, and piping, instrumentation, and housing and power electronics were less impacted. These cost reductions from economies of scale could be more significant than estimated cost reductions from manufacturing scale-up reported in literature. These results add to the knowledge base that could guide optimal system designs that balance process scale-up with plant modularization and numbering-up. We also estimate that scaling up BOP could potentially lower the levelized cost of hydrogen (LCOH) by $\$$1.7-$\$$4.6/kg, depending on the scale-up magnitude and the plant capacity factor.

08 HYDROGEN↗

DOE OSTI2022

Technoeconomic Analysis of High-Value, Crystalline Silicon Photovoltaic Module Recycling Processes

Recycling is an important circular economy strategy, and for photovoltaics (PV), the one that has received the greatest research attention. Recycling of PV modules is required in Europe; everywhere else it competes in the market of end-of-life options, where cost is a primary decision factor. The vast majority of PV modules sold globally are crystalline-silicon (c-Si); most of the rest of the market are cadmium telluride thin film modules whose primary manufacturer runs its own commercial-scale recycling program. While many different c-Si recycling approaches and technologies have been proposed, they generally lack accompanying cost estimates or enough process information to model costs. Herein we develop detailed estimates of seven categories of capital and operating costs along with estimates of revenue from recovered materials for each step in two proposed recycling processes for c-Si PV modules. Using these results, we develop a hypothetical third recycling process merging process steps from the original two, estimate surcharges required to achieve minimum sustainable prices for each recycling process, as well as consider how economies of scale could reduce costs. Increasing the purity of and identifying higher-value markets for recovered materials are approaches to reducing costs and increasing recycling rates in voluntary markets.

crystalline silicon↗

DOE OSTI2024

Improved Manufacturability and Throughput of Ultra- Transparent, Super-Insulating Aerogels

AeroShield Materials produces a novel silica aerogel material with exemplary thermal performance and unprecedented optical clarity, offering the potential for super-insulating fenestration and insulated glass to reduce thermal losses in the built environment by billions of dollars every year. One of the most significant challenges facing AeroShield today is the total amount of time that is required to produce large monolithic aerogel samples. This overall process can require as much as 144 hours total, which can significantly hinder scale-up to an economically viable product. The purpose of this Phase 1 research was to continue development of our novel aerogel manufacturing process to reduce material processing time by up to 10x, greatly improving product throughput and reducing cost. AeroShield’s manufacturing process can be divided into 4 major stages, each with their own distinct set of parameters and time requirements. Under this Phase 1 award, AeroShield was able to identify and optimize a number of these parameters, including molding materials, solvent rinse conditions, critical point drying time, and annealing conditions. AeroShield also performed thorough analyses on how these optimized parameters affected important final characteristics of the gels, including optical clarity, thermal conductivity, and dimensional stability. This campaign culminated in the production of laboratory scale aerogel samples using significantly lower process times of both 36 and 18 total hours, which represent Phase 1 Target and Stretch goals. In order to achieve widespread market adoption, monolithic sheets of the aerogel material must be made to industry-standard sizes (8’ x 12’) at a cost that provides 5-7 year or less breakeven energy savings for consumers (<$2 sq/ft). The work performed under this Phase 1 award shows that time and materials required to make aerogel samples, which make up a significant portion of their overall cost, can be greatly reduced without sacrificing quality. AeroShield plans to use these optimized processes to produce larger, product-relevant sized aerogels in order to achieve target final material costs.

Wilke, Kyle↗

NASA NTRS2011

On-Orbit Solar Dynamics Observatory (SDO) Star Tracker Warm Pixel Analysis

This paper describes the process of identification and analysis of warm pixels in two autonomous star trackers on the Solar Dynamics Observatory (SDO) mission. A brief description of the mission orbit and attitude regimes is discussed and pertinent star tracker hardware specifications are given. Warm pixels are defined and the Quality Index parameter is introduced, which can be explained qualitatively as a manifestation of a possible warm pixel event. A description of the algorithm used to identify warm pixel candidates is given. Finally, analysis of dumps of on-orbit star tracker charge coupled devices (CCD) images is presented and an operational plan going forward is discussed. SDO, launched on February 11, 2010, is operated from the NASA Goddard Space Flight Center (GSFC). SDO is in a geosynchronous orbit with a 28.5 inclination. The nominal mission attitude points the spacecraft X-axis at the Sun, with the spacecraft Z-axis roughly aligned with the Solar North Pole. The spacecraft Y-axis completes the triad. In attitude, SDO moves approximately 0.04 per hour, mostly about the spacecraft Z-axis. The SDO star trackers, manufactured by Galileo Avionica, project the images of stars in their 16.4deg x 16.4deg fields-of-view onto CCD detectors consisting of 512 x 512 pixels. The trackers autonomously identify the star patterns and provide an attitude estimate. Each unit is able to track up to 9 stars. Additionally, each tracker calculates a parameter called the Quality Index, which is a measure of the quality of the attitude solution. Each pixel in the CCD measures the intensity of light and a warns pixel is defined as having a measurement consistently and significantly higher than the mean background intensity level. A warns pixel should also have lower intensity than a pixel containing a star image and will not move across the field of view as the attitude changes (as would a dim star image). It should be noted that the maximum error introduced in the star tracker attitude solution during suspected warm pixel corruptions is within the specified 36 attitude error budget requirement of [35, 70, 70] arcseconds. Thus, the star trackers provided attitude accuracy within the specification for SDO. The star tracker images are intentionally defocused so each star image is detected in more than one CCD pixel. The position of each star is calculated as an intensity-weighted average of the illuminated pixels. The exact method of finding the positions is proprietary to the tracker manufacturer. When a warm pixel happens to be in the vicinity of a star, it can corrupt the calculation of the position of that particular star, thereby corrupting the estimate of the attitude.

Felikson, Denis↗

NASA NTRS2016

Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m Class System

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. The HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to 15m-class system. Two complications in working with handmade textiles structures are the non-linearity of the materials and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the materials out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m class HIAD. In this paper, the challenges and associated mitigation plans related to scaling up the HIAD stacked-torus aeroshell to a 15m class system will be discussed. In addition, the benefits of enlarging the structure will be further explored.

Decellerators↗

DOE OSTI2021

Renewable Energy for Industrial Environmental Management

Costs for renewable energy technologies have declined rapidly in the past decade and their use for residential, commercial, and utility scale electricity has grown exponentially as they become cost competitive. Simultaneously, industrial and manufacturing processes have been increasingly seeking ways to reduce emissions and operational costs in highly competitive sectors. With these combined drivers of lower cost and reduced environmental impact, renewable energy may become a viable energy provider for industrial processes such as oil and gas, mining, chemical refining, food production, and manufacturing. Renewable energy technologies may also partner with other reduced emission energy sources, such as small modular nuclear reactors and carbon capture and utilization, to create cleaner and circular industrial systems for reduced resource use. The Joint Institute for Strategic Energy Analysis (JISEA), which is a partnership of the National Renewable Energy Laboratory (NREL) and five universities and others, has been studying to potential for application of clean energy technologies to the heterogenous energy demands in industry. Dr. Jill Engel-Cox will present an overview of NREL and JISEA, the status and potential future of renewable energy technologies, and collaborations with the oil and gas industry and other industrial sectors to improve their environmental performance and reduce operational costs.

ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Exploring New Ways to Classify Industries for Energy Analysis and Modeling

As the US moves closer to embracing a net zero greenhouse gas emissions position, combustion processes outside the power sector are becoming urgent concerns. Industry is an important end user of energy and relies on fossil fuels used directly for process heating and as feedstocks for a diverse range of applications. Fuel and energy use by industry is heterogeneous, meaning that even a single product group can vary broadly in its production routes and associated energy usage. In the US, the North American Industry Classification System (NAICS) serves as the basis for data collection and reporting. In turn, data based on NAICS is the foundation of most US energy modeling. Thus, the effectiveness of NAICS at representing energy use is a limiting condition for plans to improve energy efficiency and alternatives to fossil fuels in industry. Facility-level data to build more detail into heterogeneous sectors is scarce. This work explores alternative classification schemes for industry based on energy use characteristics, and provides a validation of an approach to make facility-level energy use estimates based on publicly available data from the greenhouse gas reporting program. First, several approaches to industrial taxonomies and their usefulness for industrial energy modeling are summarized. Data from Industrial Assessment Centers is analyzed using unsupervised machine learning techniques to detect clusters. Cladistics, an approach from biology, is adapted to energy and process characteristics of industries. A cladogram is presented for evolutionary directions in the iron and steel sector. Cladograms are a promising tool for constructing scenarios and summarizing directions of sectoral innovation. Finally, validation is performed for facility-level energy estimates from the US EPA Greenhouse Gas Reporting Program. This validation assists in making this data source available for use in energy modeling. Together, this work explores alternative approaches for categorizing industries in a way that aids understanding energy use, and presenting pathways for the future.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗

NASA NTRS2017

Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails

State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.

Fernandez, Juan M.↗

DOE OSTI2022

Mapping the Opportunity Space to Model the Circular Economy Using Tools Funded by the DOE Office of Energy Efficiency and Renewable Energy

An increasing rate of material consumption and a growing population mean that the Earth's supply of natural resources is witnessing an unsustainable and unprecedented demand. This forces us to find solutions that ensure the availability of resources for sustenance of our society in the years to come. Actors from various backgrounds are addressing these challenges from their own perspectives: engineers are developing efficient manufacturing processes, designers are creating lightweight and durable products, educators are incorporating sustainable thinking in their curricula, policymakers are finding interdisciplinary solutions that benefit society at large, etc. Circular economy (CE) is one such approach to resource use that aims to move away from the linear material use framework of "take-make-waste" to a more circular and interdependent system where product, material and resource use is maximized to avoid unnecessary social, economic, and environmental costs. The purpose of this report is to explain how to approach evaluating the circular economy and to help researchers identify existing tools that can be used or that can serve as starting points for their research needs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗