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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

An Abrasive Wear Model of Knife Milling to Predict the Impact of Material Properties and Milling Parameters on Knife Edge Recession

A workable analytical abrasion model that relates critical knife-mill process parameters (geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) was formulated to model wear of knives in knife-milling systems. Results of the model were compared to experimental observations of the edge recession of knives used in a knife mill marketed by Eberbach. Results showed good agreement between the predicted and measured shape of a worn knife and showed that a quality-by-design approach can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

36 MATERIALS SCIENCE↗

An Abrasion Wear Model of Rotary Shear Comminution of Biomass Feedstock

The research team formulated a workable analytical abrasion model that relates critical rotary shear process parameters (shear geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) that enabled us to model the wear of shear cutters in a rotary shear milling system developed by Forest Concepts. We compared results of the model to experimental observations of the shape of rotary shear cutters used in a Forest Concept Crumbler® shear mill. Results showed good agreement between the predicted and measured shape of a worn cutter; thus, a quality-by-design (QbD) approach can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

42 ENGINEERING↗

Bay Area Regional Energy: Network Integrated Commercial Retrofits (BRICR) Project. Final Report

The BRICR project applied large-scale building energy modeling concepts with the aim of reducing the cost of energy efficiency targeting, design, and project development, and measurement of energy savings for energy efficiency programs implemented by local governments that serve small and medium commercial buildings (SMB). The project leveraged the services and resources of existing local government energy programs serving disadvantaged and hard-to-reach SMB customers. In contrast to programs run by utilities, local government programs generally do not have direct access to energy billing records for an entire class of customers in a geographic area, which prior research demonstrated useful for large-scale building energy model baseline development and calibration. , However, local governments are rich in public records that offer important clues about physical attributes and uses that, along with behavior, determine energy use. Relying only on public records, BRICR demonstrated development of credible baseline energy models for 3,792 office, retail, and hotel buildings. Publicly disclosed annual energy use data from a local energy benchmarking program and anonymized data from the Building Performance Database, the nation’s largest dataset about energy-related characteristics of buildings, were utilized to validate and calibrate energy models via an innovative method comparing distributions of energy intensity by fuel type for portfolios of buildings of similar size, vintage, and use. Portfolio calibration does not provide certainty that an energy model fits an individual building; the method is useful when billing data is not accessible – a common situation for researchers, energy service providers and ESCOs, local governments, and any party other than a utility. A software component was developed, the BRICR gem, which automates simulation when relevant data is added or edited by the user to a file saved in the standardized BuildingSync XML schema for energy audit data. The component was demonstrated as a simplified means to generate a mass of energy models corresponding to public records containing basic attributes such as building scale, location, use, year built, and aspect ratio in combination with building energy code prototype data corresponding to use and vintage. The component was also demonstrated as a simplified means to automate energy simulation when attributes are revised; the intention was to enable iterative improvement of the baseline model and energy savings estimates for common energy conservation measures as users revise relevant attributes based on their observations. In the context of institutional change and uncertainty for the participating local government energy programs, 13 whole building retrofits were completed. Impacts were measured by applying the CalTRACK2.0 methods to standardize measurement of normalized metered energy consumption. The GRIDMeter methods of stratified sampling and individual load shape analysis were applied to adjust for impacts of the effect of COVID-19 on retrofitted buildings in the context of all local buildings of similar size and use. Excluding impacts of the pandemic, retrofitted buildings demonstrated between 1.6% and 25.1% reduction in energy use. The project contributed use cases and feedback that helped inform evolution of the software tools and data formats that were combined for the first time in the BRICR project.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Synergistic Coating-Alloy Development for Harsh Environments

The primary objective of the work was to demonstrate model alloy-coating combinations with: A. Improved oxidation resistance with a barrier coating by at least 2x vs. uncoated alloy; B. Uniform coating on a greater than 100:1 aspect ratio structure; and C. Expected reduction of lifecycle cost of a component of >25% based on customer inputs. All three objectives have been achieved.

36 MATERIALS SCIENCE↗

Simulating Wind Around Isolated Buildings with the System for Atmospheric Modeling

A method to represent the flow around obstacles such as buildings is implemented in the System for Atmospheric Modeling (SAM). The method, which we call a Quasi-Solid Box Method (QSBM), introduces a simple modification to the anelastic equations that forces the flow to stagnate within the obstacle's boundaries. The performance of the modified SAM is evaluated using CEDVAL (Compilation of Experimental Data for Validation of Microscale Dispersion Models) wind tunnel measurements of the wind and tracer dispersion around a single rectangular building. All major observed features of the flow are quite well reproduced. The dispersion of the tracer released at the building base is also simulated. The results of simulation of a flow around a cubic building rotated by 45 degrees relative to the flow, and around a building in the form of a cylinder of aspect ratio of one, are also presented.

54 ENVIRONMENTAL SCIENCES↗

Modeling the Yaw Behavior of Tail Fins for Small Wind Turbines: November 22, 2021 - May 21, 2024

This report describes the aerodynamic modelling of the yaw behavior of tail fins for small wind turbines (SWTs). The analysis is based on unsteady slender body theory (USBT) and is formulated to be used with the proposed tail fin module to be added to OpenFAST. Linearized USBT, which has been applied in the past to SWT tail fins, is developed in three main ways. First, USBT is extended to high yaw angles and aspect ratios by modelling the associated nonlinear vortex dynamics and the chordwise load distribution respectively. Second, we consider the effect of time-varying wind speed. The extended theory is compared to recent unpublished measurements at the University of Perugia, Italy, for the yaw behavior of delta, elliptical, and rectangular tail fins without a rotor and nacelle. The fins were released from initial yaw angles of -40 degrees and -80 degrees ; the latter is of sufficient magnitude to show the importance of the nonlinear yaw dynamics. Further, the friction in the model tail fin bearings was measured and modelled. The constants in the aerodynamic models were taken from the literature but significant improvement in accuracy is achieved by using system identification techniques to optimize the values. This leads to the third main finding: extended USBT is accurate for all generic tail fin shapes that we considered and is, therefore, very suitable for inclusion in aeroelastic codes for SWTs. The final development is of a general nonlinear equation for yaw response that is simpler than the extended USBT and is also suitable for inclusion in OpenFAST. The two nonlinear models are used to highlight the geometric requirements for good tail fin design.

distributed wind↗

Time-Dependent Boundary Modeling to Inform Design of SPARC Diagnostic and Actuators

The purpose of this work was to inform the design of diagnostic and actuator systems for a new experimental facility for Commonwealth Fusion Systems (CFS), called SPARC [Creely2020], using time-dependent plasma boundary simulations with the Scrape Off Layer Plasma Simulator (SOLPS) code [Wiesen2015]. The SPARC tokamak is a device that aims to demonstrate fusion energy production and high-field plasma operating scenarios. The developed technologies will be incorporated into a net-electricity pilot that will demonstrate approximately 200MW of electric power. A major difference from other private industry fusion companies is the use of a standard aspect ratio, but at a high magnetic field strength, which provides a well-established physics basis and a modest extrapolation to reactor operation. Time-dependent simulations were used to inform the design of main-chamber plasma facing components, which are protected by feedback control of the heat and particle loads during high power operation. The simulations provide the timescales and magnitudes of plasma and neutral particle response useful for determining the position and operation of diagnostics and actuators that will enable control. The plasma response and phase-space diagrams also provide input into advanced model-based control schemes, which are envisioned for later SPARC operation. Model-based control can reduce the risk of component failure, which would require expensive in-situ repairs and the associated delays, by predicting the system response to actuators over a short time-horizon.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Analysis of Cutter Blade Wear in Rotary Shear Mills

Following development of an analytical abrasive wear model to predict wear of components in a rotary shear mill, the team used a finite element analysis (FEA) approach to calculate forces and loads acting on particles responsible for abrasive wear. The analytical model related critical rotary shear process parameters (shear geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) that enabled us to model the wear of shear cutters in a rotary shear milling system developed by Forest Concepts. With proper knowledge of the forces acting between abrasive particles and cutter components built into it, the model can accurately predict wear of the cutters and provides a quality by design (QbD) approach to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches. During this reporting period, researchers at Oak Ridge National Laboratory applied an FEA package to simulate the local stresses and forces between an abrasive silica particle and two rotary shear cutters as the distance between the cutters decreases. The output of the FEA was used to provide more accurate projections of the loads applied to the particles in the analytical wear model. Comparison of the FEA force calculations are in good agreement with the loads assumed in the analytical predictions.

36 MATERIALS SCIENCE↗

Annual report for DOE VTO

Carbon fiber (CF)/polymer composites are a transformative class of high-performance, lightweight material, where high aspect-ratio CFs reinforce a polymer matrix and exceed the strength of steel alloys at a fraction of the density. Despite the advantages of such a class of material, the broader implementation of CF composites in a range of automotive, aerospace, and energy applications is hindered by limitations of current manufacturing methods. These current techniques (e.g., hand lay-up, wet filament winding) are costly and impose severe limitations on fiber placement, orientation, and angle, and thus a composite’s ultimate properties. Today’s CF composites are expensive to manufacture, limited in form factor, and utilize costly and sub-optimal continuous filament CF. Advanced additive manufacturing (AM) processes, combined with computational design optimization and new approaches to resin development, offer alternative design and manufacturing paradigms that have the realistic potential to lift these constraints. Such integrated AM approaches could thus help to realize the full potential of CF composite materials. One relevant application of CF composite materials where manufacturing constraints limit the cost-benefit ratio is in the manufacture of high-performance composite pressure vessels for onboard compressed natural gas (CNG) storage. Current CNG storage vessels (Types 3–5) are made from load-bearing filament-wound carbon-fiber composite and are ~3.5 times as expensive as an all-metallic Type-1 vessel. This cost is invariably tied to the complex and labor-intensive nature of conventional filament winding processes and the large volumes of expensive high tensile-strength CF tow feedstock required in manufacture. Our proposed approach to CNG storage vessel manufacture is based on a combination of AM technologies for CF composite printing and design optimization tools that were pioneered at Lawrence Livermore National Laboratory (LLNL), with advances in resin/composite formulation enabled by chemical and nano-material modification. Through the successful development of this technology, LLNL seeks to demonstrate the capability for advanced CNG storage vessel manufacture at reduced cost with no reduction in performance versus the most advanced, extant Type-5 designs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗

Shear thinning rheology in a concentrated suspension of fibers: the role of attractive interactions

Fiber-reinforced composites are ubiquitously encountered in the engineering, automobile, and aerospace industries. Fabrication of these composites requires the mixing of fibers dispersed in a liquid, and the final structure is affected by fiber properties, interactions, and flow fields. A good understanding of the rheology of fiber suspensions can aid in the design and optimization of the fabrication processes. To this end, we simulate the simple shear flow of fiber suspensions by accounting for short range lubrication, van der Waals attractive, electrostatic repulsion interactions, as well as friction between fibers. Direct numerical simulations are performed using the Immersed Boundary Method where the fibers are modeled as flexible slender bodies governed by the Euler-Bernoulli beam theory and the fluid flow is resolved using the Navier-Stokes equations. The simulation results for the suspension viscosity and yield stress are consistent with the experimental data from the literature for polyamide fiber suspensions. The shear-thinning behavior becomes stronger as we increase the magnitude of attractive interactions. Furthermore, we perform a parametric study varying fiber flexibility, volume fraction, aspect ratio, inertia and examine suspension viscosity and yield stress.

Khan, Monsurul↗

Innovative Design and Manufacturing of 2.5D Battery with High Energy and Power Density (Final Report)

The goal of this project is to develop cathode inks, to be used in additive manufacturing (AM), that lead to a low-cost, fast manufacturing processes for a new type of non-planar, 2.5D lithium-ion battery (LIB). 2.5D batteries, comprised of a high-aspect-ratio 3D electrode combined with a 2D planar electrode, can simplify the fabrication process because there is no need for the alignment steps seen in traditional 3D batteries. For the success of the two AM processes identified in this project, development of cathode inks is key component because it allows for both platforms to be evaluated in achieving high performance batteries and ease of manufacturing. The two AM processes explored in this project are direct ink writing (DIW) and templating. Both of these processes have been shown to be successful in depositing materials for traditional LIBs and will be used now for the 3D array electrode configuration as part of the 2.5D battery.

25 ENERGY STORAGE↗

Characterization of Lab-Grown Cracks for Aerosol Transmission Testing

Motivation: Determine the length and opening of two lab-grown cracks, designated as LT-14 and LT-28, representative of stress corrosion cracks in spent nuclear fuel dry storage casks to supplement future testing of gas and aerosol transport. Problem: The extreme aspect ratio of the crack length to opening requires that imaging occurs in stages with the results merged before final analysis. Method: High magnification (1500x) optical images of both sides of the two plates were acquired. 20x stitched images with LSCM were acquired, fully stitched along the length, and leveled with newly developed PLATES Method in MATLAB®. Conclusion for LT-14: Side 1 is 47.25 mm long and has 366 separate crack features with an average length of 23.50 µm and an average opening of 8.27 µm. Side 2 is 69.44 mm long and has 550 separate crack features with an average length of 81.63 µm and an average opening of 67.70 µm. Conclusion for LT-28: Side 1 is 71.95 mm long and has 1,127 separate crack features with an average length of 42.27 µm and an average opening of 10.31 µm. Side 2 is 74.88 mm long and has 520 separate crack features with an average length of 98.13 µm and an average opening of 14.99 µm. The adjacent crack on side 1 is 18.95 mm long and has 37 separate crack features with an average length of 17.46 µm and an average opening of 10.42 µm. The adjacent crack on side 2 is 26.40 mm long and has 55 separate crack features with an average length of 87.26 µm and an average opening of 48.29 µm. Each adjacent crack is approximately 26 mm from the main crack.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Nanomanufacturing of Nanophononic Devices: Ultra-high ZT Thermoelectrics for Efficient Conversion of Waste Heat

Fabrication and Characterization Summary: For this program, the team fabricated and tested silicon thermoelectric test structures that experimentally demonstrated record thermal conductivity reduction (> 85 %) without changes in electrical properties (conductivity and Seebeck coefficient). We also demonstrated the highest ever reported energy conversion efficiency for silicon thermoelectric devices. The team developed a design for 1 cm 2 die with thousands of nanophononic metamaterial structures in the form of nanowalled membranes but were unable to solve all fabrication challenges before the end of the program. Multiple aspects of the design were submitted for patent protection. Primary challenges were related to silicon-on-insulator material quality and high-aspect-ratio etching.

30 DIRECT ENERGY CONVERSION↗

Machine Learning of Plasma Science for Next Generation Microelectronics (Project Final Report)

Low temperature plasmas (LTPs) are an enabling technology behind reducing device dimensions and the continuation of Moore’s Law. It is estimated that 40-45% of all process steps necessary to manufacture semiconductor devices involve LTPs. However, challenges in plasma process design and continuous incorporation of novel materials for new device architectures are pushing the limits of what is possible with current plasma technology. For example, creating higher aspect ratio structures and etching features at the atomic scale both require finer control of the ion energy/velocity at wafer surfaces. To support these types of future innovations in the plasma processing systems that Sandia and the DOE rely upon, we have developed novel diagnostics, simulations, and machine learning capabilities to discover, characterize, and predict plasma phenomena affecting the ion energy/velocity distribution function (IEDF). These efforts also supported research program development and external collaboration with industry and academia through Sandia’s Plasma Research Facility (PRF). This report will focus on the following topics and accomplishments of this three year LDRD project, briefly summarized.

42 ENGINEERING↗

Optimizing 4d Emittance Measurements Using the Pinhole Scan Technique

Accurate measurement of electron beam emittance is essential for optimizing high-brightness electron sources. The Pinhole Scan Technique measures the 4D phase space and hence the emittance by measuring the beam profile after clipping the beam using a pinhole followed by a drift section and then scanning the beam over the pinhole. This technique has been implemented in low energy (< 200 keV) beamlines at both Cornell University and Arizona State University. However, the technique poses several practical challenges. In this work, we analyze and address key issues affecting the 4D phase space and emittance measurements using this technique. We identify and investigate sources of inaccuracies like the pinhole aspect ratio, beam divergence, position-momentum correlations in the phase space, and the point-spread-function of the detector and suggest techniques to minimize them. Our findings offer a pathway to more accurate 4D phase space characterization in advanced electron beam systems.

42 ENGINEERING↗

Development and Evaluation of a General Drag Model for Gas-Solid Flows via Deep Learning

This project presents the development and evaluation of a general drag model for gas–solid multiphase flows using deep learning techniques. A comprehensive database of more than 4,000 experimental and numerical data points for spherical and non spherical particles was compiled, incorporating geometric features such as sphericity, aspect ratio, and orientation. Several predictive approaches—including traditional em pirical correlations, machine learning, and deep neural networks—were benchmarked, with the proposed Drag Coefficient Correlation-aided Deep Neural Network (DCC DNN) demonstrating superior accuracy. To account for particle–particle interactions, additional drag data were generated using CFD-based simulations of packed and flu idized beds, leading to the development of a retrained model capable of incorporat ing volume fraction effects. Integration of the trained model with the MFiX CFD solver was achieved using FTorch, enabling drag predictions during discrete element method (DEM) simulations. Validation against experimental data for single particles and fluidized beds confirmed the model’s improved predictive ability, particularly for non-spherical geometries. While the model performed strongly under fluidized con ditions, limitations remained in unfluidized regimes, suggesting a need for expanded datasets. Overall, this study demonstrates the feasibility of combining deep learning with physics-informed CFD to improve drag modeling for gas–solid flows, with promis ing implications for scaling multiphase simulations in industrial applications.

42 ENGINEERING↗

The FastrSHWFS Project Development Motivation, Analysis, & Test Results

The recent 2020 Decadal Survey of Astronomy and Astrophysics listed habitable exoplanet imaging with future extreme adaptive optics (AO) on 30m-class telescopes as a key priority in the coming decade. However, there is a current 100x contrast gap between the best systems today and what is needed to enable this goal. Astronomical AO is a required approach to enable ground-based diffraction-limited imaging of exoplanets on future extremely large telescopes. Time lag between the end of an exposure and the application of deformable mirror commands is a major contributor to the error budget in many AO systems, and detector read time is often a large component of this lag. We present two designs for a modified Shack Hartmann wavefront sensor (SHWFS), named Focal plane Actualized Shifted Technique Realized for a SHWFS (fastrSHWFS), to reduce the time lag component. This design steers the spot pattern at the focal plane into a rectangular or linear array with a custom aspect ratio, reducing readout time. The mask with focus yields aberrated results while the mask with tip/tilt only yields some defined spots. This essay outlines the current SHWFS concept, our fastrSHWFS theoretical solution to addressing time lag, reflection and quality analysis of printed mask designs, and results from testing both masks on the High Contrast Testbed at Lawrence Livermore National Lab. This work follows the test of a previous fastrSHWFS design.

79 ASTRONOMY AND ASTROPHYSICS↗