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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 523 records · Page 29

Intelligent Optimization of the Digital Low Level RF Control System for LANSCE LINAC

The LINAC at the Los Alamos Neutron Science Center (LANSCE) accelerates protons from 750 keV to its final energy at 800 MeV via 48 radio frequency (RF) modules. However, the startup and recovery process of the low-level RF (LLRF) systems, the primary controls for the RF modules, cost significant time for the beam operation, while the process itself is highly prone to human errors. With the new conversion from the analog LLRF (aLLRF) to digital LLRF (dLLRF) system under the recent LANSCE Modernization Project, new approaches with the new dLLRF capabilities can be achieved to address this issue. We propose to develop an intelligent optimization scheme that can significantly lower the downtime caused by the LLRF systems. This directly address the MFR problem statement that asks for “innovative engineering improvements to ancillary systems such as RF and pulsed power that improve reliability, maintainability, and/or performance.”

43 PARTICLE ACCELERATORS↗

Assessment of Additive Manufacturing of Particle Accelerator [Slides]

Metal additive manufacturing of copper components has been commercialized on multiple printing modalities; including Bound Metal Deposition (BMD), Laser Powder Bed Fusion (LPBF), and Electron Beam Melting (EBM). BMD was selected at the primary printing modality for this TED because of the availability of the Markforged Metal X machine within the LANL E-2 AM research lab. Linear accelerator (LINAC) structures are similarly demonstrated technology. Accelerator structures are typically made of high purity oxygen-free electronic copper owing to the material’s high electrical and thermal conductivity. Conventionally machined and brazed, welded, or bolted designs are difficult to manufacture and require long lead times.

36 MATERIALS SCIENCE↗

Neutrino Oscillations at the NOvA Experiment

The NOvA experiment is a long-baseline neutrino oscillation experiments based at Fermi National Accelerator Laboratory in IL, USA. The experiment was designed to observe muon neutrino (muon anti-neutrino) disappearance and electron neutrino (electron anti-neutrino) appearance oscillations using a set of technological identical liquid scintillation detectors. The detectors are situated 14.6 milli-radians off-axis to the Fermilab's NuMI beam line that provides a beam of neutrinos (anti-neutrinos) to the experiment. The latest results from 3-flavor neutrino oscillation analysis from 10 years of NOvA data will be discussed in the talk.

Choudhary, Brajesh [Delhi U.]↗

Progress towards computer simulation of NiH2 battery performance over life

The long-term performance of rechargeable battery cells has traditionally been verified through life-testing, a procedure that generally requires significant commitments of funding and test resources. In the situation of nickel hydrogen battery cells, which have the capability of providing extremely long cycle life, the time and cost required to conduct even accelerated testing has become a serious impediment to transitioning technology improvements into spacecraft applications. The utilization of computer simulations to indicate the changes in performance to be expected in response to design or operating changes in nickel hydrogen cells is therefore a particularly attractive tool in advanced battery development, as well as for verifying performance in different applications. Computer-based simulations of the long-term performance of rechargeable battery cells have typically had very limited success in the past. There are a number of reasons for the lack in progress in this area. First, and probably most important, all battery cells are relatively complex electrochemical systems, in which performance is dictated by a large number of interacting physical and chemical processes. While the complexity alone is a significant part of the problem, in many instances the fundamental chemical and physical processes underlying long-term degradation and its effects on performance have not even been understood. Second, while specific chemical and physical changes within cell components have been associated with degradation, there has been no generalized simulation architecture that enables the chemical and physical structure (and changes therein) to be translated into cell performance. For the nickel hydrogen battery cell, our knowledge of the underlying reactions that control the performance of this cell has progressed to where it clearly is possible to model them. The recent development of a relative generalized cell modelling approach provides the framework for translating the chemical and physical structure of the components inside a cell into its performance characteristics over its entire cycle life. This report describes our approach to this task in terms of defining those processes deemed critical in controlling performance over life, and the model architecture required to translate the fundamental cell processes into performance profiles.

Zimmerman, Albert H.↗

Energy Absorbing Seat System for an Agricultural Aircraft

A task was initiated to improve the energy absorption capability of an existing aircraft seat through cost-effective retrofitting, while keeping seat-weight increase to a minimum. This task was undertaken as an extension of NASA ongoing safety research and commitment to general aviation customer needs. Only vertical crash scenarios have been considered in this task which required the energy absorbing system to protect the seat occupant in a range of crash speeds up to 31 ft/sec. It was anticipated that, the forward and/or side crash accelerations could be attenuated with the aid of airbags, the technology of which is currently available in automobiles and military helicopters. Steps which were followed include, preliminary crush load determination, conceptual design of cost effective energy absorbers, fabrication and testing (static and dynamic) of energy absorbers, system analysis, design and fabrication of dummy seat/rail assembly, dynamic testing of dummy seat/rail assembly, and finally, testing of actual modified seat system with a dummy occupant. A total of ten full scale tests have been performed including three of the actual aircraft seat. Results from full-scale tests indicated that occupant loads were attenuated successfully to survivable levels.

Kellas, Sotiris↗

FEED Study of CarbonCapture Inc DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat (Final Report)

The University of Illinois at Urbana-Champaign (UIUC) led this project to produce a front-end engineering design (FEED) study of an advanced Direct Air Capture and Utilization System (DACUS) system that can remove a minimum of 5,000 tonnes/yr net of carbon dioxide from air (based on cradle-to-gate LCA) and utilizing the CO 2 to produce low carbon intensity ready mix concrete. The designed system, if built, would be larger than any currently existing Direct Air Capture (DAC) collector in the U.S. Such carbon capture technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. In addition to the power sector, industrial facilities for the manufacture of steel and cement/concrete are among the major sources of anthropogenic CO 2 . DAC is a promising new technology for reducing CO 2 , a potent greenhouse gas, in the atmosphere but is expensive, in part due to the energy required to adsorb and desorb captured CO 2 during cycles. By integrating CarbonCapture Inc. (CCI) DAC modules at United States Steel's Gary Works (USS) and utilizing the site's waste heat, energy, and location this project evaluates the feasibility of utilizing the captured CO 2 and the logistics of transportation. CarbonCapture Inc. has developed an innovative DAC system using novel adsorbents to cost-effectively capture CO 2 . The captured, liquified gas will be trucked to ready-mix concrete plants within the region, the closest of which is approximately 3.5 miles away, where CarbonCure will inject it into concrete during the mixing process at the facilities. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO 3 ), permanently locking the greenhouse gas into the matrix of the building material. This FEED study demonstrated a full CO 2 value chain for DACUS from industrial facilities. It also provided a means for Visage Energy Corp. (Visage) to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. The project team also included Sargent & Lundy (S&L) to provide the constructability review and costing of the integration of the DAC with the steel plant. Ecotek Engineering USA, LLC designed the outside battery limit (OSBL) infrastructure to connect the DAC and the plant. Activities performed during the project included: (1) Project Management Plan; (2) Technology Maturation Plan (TMP); (3) Initial Workforce Readiness Plan; (4) Workforce Readiness Plan; (5) Front-End Engineering Design (FEED) Study; (6) Project Design Basis; (7) Hazards and Operability (HAZOP) Study; (8) Constructability Review; (9) Project Cost Assessment; (10) Logistics Analysis of CO 2 Transportation to the Utilization Site; (11) Business Case Analysis; (12) Life Cycle Analysis (LCA); (13) Environmental Health and Safety (EH&S) Analysis; (14) Environmental Justice Analysis; and (15) Economic Revitalization and Job Creation Outcomes Analysis. This report provides a summary of the outcomes and results of the project, which was performed between Oct. 1, 2022, through Sept. 30, 2024.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Lessons Learned on Prize Design in the Perovskite Startup Prize

In 2018, the U.S. Department of Energy's Solar Energy Technologies Office and the National Renewable Energy Laboratory set out to develop a repeatable, predictable prize model with the American-Made Challenges. A new model launched by the Solar Energy Technologies Office in March 2021 was the American-Made Perovskite Startup Prize. This new prize aimed to accelerate the growth of the domestic perovskite industry and support the rapid development of solar cells and modules that use perovskite materials. By sharing the outputs of the prize, we hope that our lessons learned will help continue to build the clean tech entrepreneurship support ecosystem and influence how a successful prize design can be achieved.

14 SOLAR ENERGY↗

Design and Analysis of Precise Pointing Systems

The mathematical models of Glovebox Integrated Microgravity Isolation Technology (g- LIMIT) dynamics/control system, which include six degrees of freedom (DOF) equations of motion, mathematical models of position sensors, accelerometers and actuators, and acceleration and position controller, were developed using MATLAB and TREETOPS simulations. Optimal control parameters of G-LIMIT control system were determined through sensitivity studies and its performance were evaluated with the TREETOPS model of G-LIMIT dynamics and control system. The functional operation and performance of the Tektronix DTM920 digital thermometer were studied and the inputs to the crew procedures and training of the DTM920 were documented.

Kim, Young K.↗

CFD Multiphysics Tool

The recent bold initiatives to expand the human presence in space require innovative approaches to the design of propulsion systems whose underlying technology is not yet mature. The space propulsion community has identified a number of candidate concepts. A short list includes solar sails, high-energy-density chemical propellants, electric and electromagnetic accelerators, solar-thermal and nuclear-thermal expanders. For each of these, the underlying physics are relatively well understood. One could easily cite authoritative texts, addressing both the governing equations, and practical solution methods for, e.g. electromagnetic fields, heat transfer, radiation, thermophysics, structural dynamics, particulate kinematics, nuclear energy, power conversion, and fluid dynamics. One could also easily cite scholarly works in which complete equation sets for any one of these physical processes have been accurately solved relative to complex engineered systems. The Advanced Concepts and Analysis Office (ACAO), Space Transportation Directorate, NASA Marshall Space Flight Center, has recently released the first alpha version of a set of computer utilities for performing the applicable physical analyses relative to candidate deep-space propulsion systems such as those listed above. PARSEC, Preliminary Analysis of Revolutionary in-Space Engineering Concepts, enables rapid iterative calculations using several physics tools developed in-house. A complete cycle of the entire tool set takes about twenty minutes. PARSEC is a level-zero/level-one design tool. For PARSEC s proof-of-concept, and preliminary design decision-making, assumptions that significantly simplify the governing equation sets are necessary. To proceed to level-two, one wishes to retain modeling of the underlying physics as close as practical to known applicable first principles. This report describes results of collaboration between ACAO, and Embry-Riddle Aeronautical University (ERAU), to begin building a set of level-two design tools for PARSEC. The "CFD Multiphysics Tool" will be the propulsive element of the tool set. The name acknowledges that space propulsion performance assessment is primarily a fluid mechanics problem. At the core of the CFD Multiphysics Tool is an open-source CFD code, HYP, under development at ERAU. ERAU is renowned for its undergraduate degree program in Aerospace Engineering the largest in the nation. The strength of the program is its applications-oriented curriculum, which culminates in one of three two-course Engineering Design sequences: Aerospace Propulsion, Spacecraft, or Aircraft. This same philosophy applies to the HYP Project, albeit with fluid physics modeling commensurate with graduate research. HYP s purpose, like the Multiphysics Tool s, is to enable calculations of real (three-dimensional; geometrically complex; intended for hardware development) applications of high speed and propulsive fluid flows.

Perrell, Eric R.↗

Vibration isolation technology: Sensitivity of selected classes of experiments to residual accelerations

Work was completed on all aspects of the following tasks: order of magnitude estimates; thermo-capillary convection - two-dimensional (fixed planar surface); thermo-capillary convection - three-dimensional and axisymmetric; liquid bridge/floating zone sensitivity; transport in closed containers; interaction: design and development stages; interaction: testing flight hardware; and reporting. Results are included in the Appendices.

Alexander, J. Iwan D.↗

The science case for an intermediate energy advanced and novel accelerator linear collider facility

It is widely accepted that the next lepton collider beyond a Higgs factory would require center-of-mass energy of the order of up to 15 TeV. Since, given reasonable space and cost restrictions, conventional accelerator technology reaches its limits near this energy, high-gradient advanced acceleration concepts are attractive. Advanced and novel accelerators (ANAs) are leading candidates due to their ability to produce acceleration gradients on the order of 1–100 GV/m, leading to compact acceleration facilities. However, intermediate energy facilities (IEF) are required to test the critical technology elements on the way towards multi-TeV-class colliders. Here a science case for a 20–100 GeV center-of-mass energy ANA-based lepton collider that can be a candidate for an intermediate energy facility is presented. The IEF can provide numerous opportunities for high energy physics studies including precision Quantum Chromodynamics and Beyond the Standard Model physics measurements, investigation of charged particle interactions with extreme electromagnetic fields, and exploring muon and proton beam acceleration. Possible applications of this collider include the studies of γγ and electron beam-fixed target/beamdump collider designs. Thus, the goal of the proposed IEF is to both carry out particle physics measurements in the 20-100 GeV ranges as well as to serve as an ANA demonstrator facility.

43 PARTICLE ACCELERATORS↗

CALPHAD-based Bayesian optimization to accelerate alloy discovery for high-temperature applications

Two crucial properties influencing the performance of high-temperature alloys are coefficient of thermal expansion (CTE) and phase constitution. It is desirable to have alloys with low CTE, which reduces CTE mismatch with the surface oxide and the likelihood of oxide spallation. Reducing the amount of brittle intermetallic phases such as Sigma (σ) enhances alloy ductility and processability. Here, we propose a multi-objective Bayesian Optimization (BO) model to simultaneously minimize CTE (at an operational temperature of 1150 °C) and T σ (temperature when the Sigma phase completely dissolves in the metal matrix), properties which are obtained from high-throughput CALculation of PHAse Diagrams (CALPHAD). The model successfully identifies several alloys with CTE ≤ 2 × 10 –5 /K and T σ ≤ 500 °C by exploring just 7% of the nickel–chromium–cobalt–aluminum–iron (Ni–Cr–Co–Al–Fe) composition space. Such multi-objective alloy design frameworks can be used to inform additive manufacturing experiments and accelerate alloy discovery for high-temperature energy applications.

36 MATERIALS SCIENCE↗

Motivation and Development of a Compact Superconducting Accelerator for X-ray Medical Device Sterilization

Fermilab is developing a compact superconducting (CSRF) accelerator as a source of a high-power, high-energy electron beam to produce an x-ray beam comparable to $\geq$ 2 MCi of cobalt-60. As part of this development, we are presently assembling a 20 kW, 1.6 MeV prototype that incorporates the four enabling technologies described below. These technologies support a heat budget that is within the capacity of commercially available cryocoolers and eliminate the need for liquid cryogens. The use of superconducting technologies promises efficiencies, wall-plug to beam, of 80% or greater. A summary of the design and progress to date will be given. In addition, we will present a review of developments within the medical device sterilization industry that are motivating the development of this technology.

43 PARTICLE ACCELERATORS↗

Deep reinforcement learning for dynamic control of fuel injection timing in multi-pulse compression ignition engines

Conventional compression-ignition (CI) engines have long offered high thermal efficiencies and torque across a wide range of loads, but often require extensive exhaust gas treatment that decreases efficiency to meet ever-increasing emissions regulations. One strategy to decrease emissions is to split the fuel injection into a series of smaller injections. In this paper, we explore a new way of discovering optimal control strategies for the next generation of CI engines using deep reinforcement learning (DRL). We outline a DRL procedure to maximize the weighted reward of engine work while minimizing end-of-cycle NO x emissions. Through the procedure outlined in this paper, we show that the DRL agent is able to reduce NO x emissions threefold while only decreasing network by 2%. We demonstrate the use of transfer learning (TL) across hierarchies of physical models to accelerate the learning process, making this approach feasible for a range of control problems within this space. This paper presents a framework and demonstration for using DRL to design control systems in technology areas such as multi-pulse engine control where a hierarchy of models combined with multi-objective rewards are used for optimal operation.

33 ADVANCED PROPULSION SYSTEMS↗

Artificial intelligence and design: Opportunities, research problems and directions

The issues of industrial productivity and economic competitiveness are of major significance in the U.S. at present. By advancing the science of design, and by creating a broad computer-based methodology for automating the design of artifacts and of industrial processes, we can attain dramatic improvements in productivity. It is our thesis that developments in computer science, especially in Artificial Intelligence (AI) and in related areas of advanced computing, provide us with a unique opportunity to push beyond the present level of computer aided automation technology and to attain substantial advances in the understanding and mechanization of design processes. To attain these goals, we need to build on top of the present state of AI, and to accelerate research and development in areas that are especially relevant to design problems of realistic complexity. We propose an approach to the special challenges in this area, which combines 'core work' in AI with the development of systems for handling significant design tasks. We discuss the general nature of design problems, the scientific issues involved in studying them with the help of AI approaches, and the methodological/technical issues that one must face in developing AI systems for handling advanced design tasks. Looking at basic work in AI from the perspective of design automation, we identify a number of research problems that need special attention. These include finding solution methods for handling multiple interacting goals, formation problems, problem decompositions, and redesign problems; choosing representations for design problems with emphasis on the concept of a design record; and developing approaches for the acquisition and structuring of domain knowledge with emphasis on finding useful approximations to domain theories. Progress in handling these research problems will have major impact both on our understanding of design processes and their automation, and also on several fundamental questions that are of intrinsic concern to AI. We present examples of current AI work on specific design tasks, and discuss new directions of research, both as extensions of current work and in the context of new design tasks where domain knowledge is either intractable or incomplete. The domains discussed include Digital Circuit Design, Mechanical Design of Rotational Transmissions, Design of Computer Architectures, Marine Design, Aircraft Design, and Design of Chemical Processes and Materials. Work in these domains is significant on technical grounds, and it is also important for economic and policy reasons.

Amarel, Saul↗

Toward milli-Newton electro- and magneto-static microactuators

Microtechnologies can potentially push integrated electro- and magnetostatic actuators toward the regime where constant forces in the order of milli-Newton (or torques in the order of micro-Newton meter) can be generated with constant inputs within a volume of 1.0 x 1.0 x 0.02 mm with 'conventional' technology. 'Micro' actuators are, by definition, actuators with dimensions confined within a millimeter cube. Integrated microactuators based on electrostatics typically have force/torque in the order of sub-micro-Newton (sub-nano-Newton meter). These devices are capable of moving small objects at MHz frequencies. On the other hand, suppose we want to move a one cubic millimeter object around with 100 G acceleration; a few milli-Newton force will be required. Thus, milli-Newton microactuators are very desirable for some immediate applications, and it challenges micromechanical researchers to develop new process technologies, designs, and materials toward this goal.

Fan, Long-Sheng↗

Quiet Spike Build-Up Ground Vibration Testing Approach

NASA's Dryden Flight Research Center uses a modified F-15B (836) aircraft as a testbed for a variety of flight research:experiments mounted underneath the aircraft fuselage. The F-15B was selected to fly Gulfstream Aerospace Corporation's (GAC)QuietSpike(TM)(QS) project; however, this experiment is very unique and unlike any of the previous testbed experiments flown on the F-15B. It involves the addition of a relatively long quiet spike boom attached to the radar bulkhead of the aircraft. This QS experiment is a stepping stone to airframe structural morphing technologies designed to mitigate sonic born strength of business jets over land. The QS boom is a concept in Which an aircraft's front-end would be extended prior to supersonic acceleration. This morphing would effectively lengthen the aircraft, reducing peak sonic boom amplitude, but is also expected to partition the otherwise strong bow shock into a series of reduced-strength, non-coalescing shocklets. Prior to flying the Quietspike(TM) experiment on the F-15B aircraft several ground vibration tests (GVT) were required in order to understand the QS modal characteristics and coupling effects with the F-15B. However, due to the project's late hardware delivery of the QS and the intense schedule, a "traditional" GVT of the mated F-1513 Quietspike(tm) ready-for-flight configuration would not have left sufficient time available for the finite element model update and flutter analyses before flight testing. Therefore, a "nontraditional" ground vibration testing approach was taken. The objective of the QuietSpike (TM) build-up ground testing approach was to ultimately obtain confidence in the F-15B Quietspike(TM) finite element model (FEM) to be used for the flutter analysis. In order to obtain the F15B QS FEM with reliable foundation stiffness between the QS and the F-15B radar bulkhead as well as QS modal characteristics, several different GVT configurations were performed. EAch of the four GVT's performed had a specific objective. The overall intent was to provide adequate data which would replicate a "traditional" F-15B QS GVT with actual ready-for-flight hardware. NASA Dryden was tasked with the conduct of the 1st, 2nd and 4th GVT and the 3rd GVT was GAC's responsibility. In order for this build-up GVT approach to be feasible, it was absolutely critical that each GVT configuration matched as closely as possible the connection interface configuration between the and aircraft bulkhead.

Spivey, Natalie D.↗

Dispenser Reliability: Materials R&D. A Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) Report

Dispensers are the top cause of maintenance events and down-time at hydrogen fueling stations. In an effort to help characterize and enable improvements in dispenser reliability, an extensive accelerated lifetime testing set-up was designed and built at NREL involving components typically part of dispensing operations at fueling stations. Device Under Test (DUTs) included different components such as normally open valves, normally closed valves, fueling nozzles, breakaways devices and filters. Conditions of testing included pressures, and flow rates similar to light duty fuel cell electric vehicles fueling at -40°C, and -20°C for thousands of cycles in hydrogen. Tested components (failed and non-failed) were disassembled at SNL and polymeric O-rings were carefully retrieved and cataloged for chemical and physical characterization. Data collected was compared to similar O-rings from unexposed or non-tested components for hydrogen effects, and failure modes. Degradation analyses, based on select polymer chemistries common across all component types, their location within components, visual assessment of damage coupled with strong hydrogen effects from chemical characterization, was completed and presented to NREL and DOE. Overall, the failure rate amongst the components was not as high as expected for the test conditions. Among the component types tested, breakaways were the most susceptible to damage under these test conditions, with fueling nozzles a close second. The proper combination of selection of the right polymer and optimum component design was found to make a strong difference in component reliability under severe dispenser operating conditions. Physical degradation of polymers, rather than chemical changes due to low temperature hydrogen exposure, is more prevalent as failure mode for these test conditions. The nature and the extent of the degradation was much less at -20°C as compared to -40°C. The damage and failure rates were higher at lower temperatures than at higher test temperatures. As expected, increasing the number of cycles at the lowest test temperature (-40°C) increased damage. This indicates that cycling at the low temperature of -40°C required by SAE J2601 can reduce component life in fuel dispensing operations

08 HYDROGEN↗