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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 541 records · Page 30

Integral Ring Carbon-Carbon Piston

An improved structure for a reciprocating internal combustion engine or compressor piston fabricate from carbon-carbon composite materials is disclosed. An integral ring carbon-carbon composite piston, disclosed herein, reduces the need for piston rings and for small clearances by providing a small flexible, integral component around the piston that allows for variation in clearance due to manufacturing tolerances, distortion due to pressure and thermal loads, and variations in thermal expansion differences between the piston and cylinder liner.

Northam, G. Burton↗

Numerical Modelling of a Two-Body Point Absorber Featuring Variable Geometry

This work presents a novel wave energy converter (WEC) device concept that incorporates variable geometry modules into a two-body point absorber type WEC. The variable geometry modules consist of air inflatable bags in the surface float and a water inflatable ring in the reaction body. The variable geometry floats are able to provide greater control over the device hydrodynamics; they can be inflated or deflated to emphasize either power absorption or load shedding. The device geometry is controlled in a quasi-static fashion, while the power take-off (PTO) unit is controlled on a wave-to-wave timescale. The surface float is tethered directly to the submerged reaction body through PTO tether lines. A linear time-domain analysis, conducted using open-source Wave Energy Converter (WEC-Sim) software, was used to estimate the absorbed power of the WEC in sea states defined by the Wave Energy Prize. WEC power performance was weighted against the expected capital cost of building the load bearing structure of the device, providing an estimated ACE value. The inclusion of the variable geometry modules was shown to be effective in altering the device geometry to improve power capture with a near proportional increase in expected costs, providing a nearly constant power-to-cost ratio.

cost of energy↗

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

Depolymerization of Cross-Linked Polybutadiene Networks in Situ Using Latent Alkene Metathesis

We report a novel approach whereby cross-linked polybutadiene (PB) networks can be depolymerized in situ based on thermally activated alkene metathesis. A commercially available latent Ru catalyst, HeatMet, was compared to the common second-generation Hoveyda–Grubbs catalyst, HG2, in the metathetic depolymerization of PB. HeatMet was found to possess exceptional stability and negligible activity toward PB under ambient conditions, in solution and in bulk. This enabled cross-linked networks to be prepared containing homogeneously distributed Ru catalyst. The dynamic mechanical properties of networks containing HeatMet and cross-linked using alcohol–isocyanate or thiol–ene chemistry were evaluated during cross-linking and post-cross-linking under isothermal and nonisothermal heating. In both cases, above minimum catalyst loadings ranging from 0.004 to 0.024 mol %, the networks exhibited rapid degelation into a soluble oil upon heating to 100 °C. At these temperatures, extensive depolymerization of the PB segments through ring-closing metathesis of 1,4/1,2 diads by the activated HeatMet introduced network defects in significantly greater proportion than the original number of cross-links. The in situ depolymerization of cross-linked PB networks through latent catalysis, as described here, may enable facile disposal and recycling of PB encapsulants and adhesives, among other applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Polyalkenamers as Drop-In Additives for Ring-Opening Metathesis Polymerization: A Promising Upcycling Paradigm

Here we report a distinct strategy to upcycle waste polyalkenamers such as polybutadiene into new, performance-advantaged materials by using them as drop-in additives for ring-opening metathesis polymerization (ROMP). The polyalkenamers serve as competent chain-transfer agents in ROMPs of common classes of cyclic olefin monomers, facilitating good molecular weight control, allowing low Ru catalyst loadings, and enabling efficient incorporation of the polyalkenamer into the synthesized polymeric material. We successfully demonstrate ROMP using model polyalkenamers and translate these learnings to leverage commercial polybutadiene and acrylonitrile butadiene styrene (ABS) as chain transfer agents for ROMP copolymerizations. Critically, our strategy is shown to be highly efficient and operationally simple, quantitatively incorporating the polyalkenamer and inheriting aspects of its thermomechanical performance. Our results highlight a promising pathway for the upcycling of polyalkenamers and provide an alternative to existing deconstruction and functional upcycling strategies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

The Finite Strain Johnson Cook Plasticity and Damage Constitutive Model in ALEGRA.

A finite strain formulation of the Johnson Cook plasticity and damage model and it's numerical implementation into the ALEGRA code is presented. The goal of this work is to improve the predictive material failure capability of the Johnson Cook model. The new implementation consists of a coupling of damage and the stored elastic energy as well as the minimum failure strain criteria for spall included in the original model development. This effort establishes the necessary foundation for a thermodynamically consistent and complete continuum solid material model, for which all intensive properties derive from a common energy. The motivation for developing such a model is to improve upon ALEGRA's present combined model framework. Several applications of the new Johnson Cook implementation are presented. Deformation driven loading paths demonstrate the basic features of the new model formulation. Use of the model produces good comparisons with experimental Taylor impact data. Localized deformation leading to fragmentation is produced for expanding ring and exploding cylinder applications.

42 ENGINEERING↗

Calculation of the longitudinal aerodynamic characteristics of wing-flap configurations with externally blown flaps

A theoretical investigation was carried out to extend and improve an existing method for predicting the longitudinal characteristics of wing flap configurations with externally blown flaps (EBF). Two potential flow models were incorporated into the prediction method: a wing and flap lifting-surface model and a turbofan engine wake model. The wing-flap model uses a vortex-lattice approach to represent the wing and flaps. The jet wake model consists of a series of closely spaced vortex rings normal to a centerline which may have vertical and lateral curvature to conform to the local flow field beneath the wing and flaps. Comparisons of measured and predicted pressure distributions, span load distributions on each lifting surface, and total lift and pitching moment coefficients on swept and unswept EBF configurations are included. A wide range of thrust coefficients and flap deflection angles is considered at angles of attack up to the onset of stall. Results indicate that overall lift and pitching-moment coefficients are predicted reasonably well over the entire range. The predicted detailed load distributions are qualitatively correct and show the peaked loads at the jet impingement points, but the widths and heights of the load peaks are not consistently predicted.

Mendenhall, M. R.↗

FDDI network test adaptor error injection circuit

An apparatus for injecting errors into a FDDI token ring network is disclosed. The error injection scheme operates by fooling a FORMAC into thinking it sent a real frame of data. This is done by using two RAM buffers. The RAM buffer normally accessed by the RBC/DPC becomes a SHADOW RAM during error injection operation. A dummy frame is loaded into the shadow RAM in order to fool the FORMAC. This data is just like the data that would be used if sending a normal frame, with the restriction that it must be shorter than the error injection data. The other buffer, the error injection RAM, contains the error injection frame. The error injection data is sent out to the media by switching a multiplexor. When the FORMAC is done transmitting the data, the multiplexor is switched back to the normal mode. Thus, the FORMAC is unaware of what happened and the token ring remains operational.

Eckenrode, Thomas↗

CO 2 capture from wet flue gas using a water-stable and cost-effective metal-organic framework

We report the use of MIL-120 as a water-stable and cost-effective metal-organic framework (MOF) for selectively capturing CO 2 from wet flue gas. Synthesized using inexpensive and environmentally benign reagents in water, MIL-120 possesses one-dimensional pores decorated with hydroxyl-bridged Al(III) ions and benzene rings with an interstitial spacing of 4.78 Å. Carbon dioxide isotherms show steep uptake at low pressure, and the affinity of MIL-120 for CO 2 is 44 kJ mol –1 . CO 2 -loading 13 C solid-state nuclear magnetic resonance and Fourier transform infrared spectra tracking the sorption of CO 2 into MIL-120 revealed that the interplay of pore size, functionality, and dimensionality is vital for CO 2 restriction within the pores of MIL-120. Breakthrough experiments reveal that MIL-120 can capture CO 2 from dry and wet flue gas with uptake capacities of 1.215 and 1.118 mmol g –1 , respectively. Our work highlights the synthetic benefits of MIL-120 and elucidates its selective capture of CO 2 from wet flue gas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Simultaneous Reduction of NOx and Fuel Consumption for Off-Road Powertrains

Simultaneously reducing criteria pollutants and fuel consumption is important for clean air and improving vehicle total cost of ownership. The goal of this effort was focused on a 90% NOx reduction and 10% fuel savings for an off-road 407 kW diesel engine. The baseline was a production Fiat Powertrain 13L engine and aftertreatment system meeting 0.4 g/kW-hr NOx. The baseline system was quantified over the NRTC, RMC, new low load cycle and five field cycles. A next generation engine was built incorporating several fuel-efficient design features, including a higher compression ratio, increased fuel-rail pressure, low-friction piston rings, and a high-efficiency variable-geometry turbocharger. Cylinder deactivation and EGR pump technologies were added to this engine as well. The combination was optimized prior to adding advanced aftertreatment systems, showing the trade-off of engine out NOx and exhaust temperature. Two next-generation catalyst technologies were employed into a LO-SCR plus main SCR system, both with and without an electric heater upstream of the LO-SCR. These catalysts were hydrothermally aged to simulate significant field use. Dual SCR dosing with newly developed controls played a critical role in achieving the proper split between the upstream LO-SCR and the downstream main SCR. Adding a next generation mixer for the downstream SCR proved essential in obtaining the final results. The optimal configuration required adding an electric heater to elevate the exhaust temperature at the LO-SCR for early cycle NOx reduction. The final results showed a 94.8% NOx reduction and 15.7% fuel savings on the composite NRTC.

McCarthy, James [Eaton Corporation]↗

Joint for Rapid Structural Assembly

Quickly attaching joint used in variety of truss structures. Split ring made in one piece and split radially after final machining. Mating tapers on split ring and endbells small: approximately 7 degrees. Tapers of this range permit high internal preloads to be obtained, yet parts easily separated when collar released. Results from tests on developmental model indicate load-displacement response linear and substantial preloading accomplished. Quickly-erecting truss structures have variety of applications, from Earth to space-station keel beams, antenna masts, and large platforms.

Rhodes, M. D.↗

An integrated autonomous rendezvous and docking system architecture using Centaur modern avionics

The avionics system for the Centaur upper stage is in the process of being modernized with the current state-of-the-art in strapdown inertial guidance equipment. This equipment includes an integrated flight control processor with a ring laser gyro based inertial guidance system. This inertial navigation unit (INU) uses two MIL-STD-1750A processors and communicates over the MIL-STD-1553B data bus. Commands are translated into load activation through a Remote Control Unit (RCU) which incorporates the use of solid state relays. Also, a programmable data acquisition system replaces separate multiplexer and signal conditioning units. This modern avionics suite is currently being enhanced through independent research and development programs to provide autonomous rendezvous and docking capability using advanced cruise missile image processing technology and integrated GPS navigational aids. A system concept was developed to combine these technologies in order to achieve a fully autonomous rendezvous, docking, and autoland capability. The current system architecture and the evolution of this architecture using advanced modular avionics concepts being pursued for the National Launch System are discussed.

Nelson, Kurt↗

Modeling of rolling element bearing mechanics. Computer program user's manual

This report provides the user's manual for the Rolling Element Bearing Analysis System (REBANS) analysis code which determines the quasistatic response to external loads or displacement of three types of high-speed rolling element bearings: angular contact ball bearings, duplex angular contact ball bearings, and cylindrical roller bearings. The model includes the defects of bearing ring and support structure flexibility. It is comprised of two main programs: the Preprocessor for Bearing Analysis (PREBAN) which creates the input files for the main analysis program, and Flexibility Enhanced Rolling Element Bearing Analysis (FEREBA), the main analysis program. This report addresses input instructions for and features of the computer codes. A companion report addresses the theoretical basis for the computer codes. REBANS extends the capabilities of the SHABERTH (Shaft and Bearing Thermal Analysis) code to include race and housing flexibility, including such effects as dead band and preload springs.

Greenhill, Lyn M.↗

Modeling of rolling element bearing mechanics. Theoretical manual

This report documents the theoretical basis for the Rolling Element Bearing Analysis System (REBANS) analysis code which determines the quasistatic response to external loads or displacement of three types of high-speed rolling element bearings: angular contact ball bearings; duplex angular contact ball bearings; and cylindrical roller bearings. The model includes the effects of bearing ring and support structure flexibility. It is comprised of two main programs: the Preprocessor for Bearing Analysis (PREBAN) which creates the input files for the main analysis program; and Flexibility Enhanced Rolling Element Bearing Analysis (FEREBA), the main analysis program. A companion report addresses the input instructions for and features of the computer codes. REBANS extends the capabilities of the SHABERTH (Shaft and Bearing Thermal Analysis) code to include race and housing flexibility, including such effects as dead band and preload springs.

Merchant, David H.↗

ARPA-E PERFORM datasets

Time-coincident load, wind, and solar data including actual and probabilistic forecast datasets at 5-min resolution for ERCOT, MISO, NYISO, and SPP. Wind and solar profiles are supplied for existing sites as well as planned sites based on interconnection queue projects as of 2021. For ERCOT actuals are provided for 2017 and 2018 and forecasts for 2018, and for the remaining ISOs actuals are provided for 2018 and 2019 and forecasts for 2019. There datasets were produced by NREL as part of the ARPA-E PERFORM project, an ARPA-E funded program that aim to use time-coincident power and load seeks to develop innovative management systems that represent the relative delivery risk of each asset and balance the collective risk of all assets across the grid. For more information on the datasets and methods used to generate them see https://github.com/PERFORM-Forecasts/documentation.

5-min data↗

An equivalent circuit model and power calculations for the APS SPX crab cavities

An equivalent parallel resistor-inductor-capacitor (RLC) circuit with beam loading for a polarized TM110 dipole-mode cavity is developed and minimum radio-frequency (rf) generator requirements are calculated for the Advanced Photon Source (APS) short-pulse x-ray (SPX) superconducting rf (SRF) crab cavities. A beam-loaded circuit model for polarized TM110 mode crab cavities was derived. The single-cavity minimum steady-state required generator power has been determined for the APS SPX crab cavities for a storage ring current of 200mA DC current as a function of external Q for various vertical offsets including beam tilt and uncontrollable detuning. Calculations to aid machine protection considerations were given.

43 PARTICLE ACCELERATORS↗

Mbtrack2 - Application on EIC 5GE V Electron Ring Reverse Phase Configuration

In this paper, we present a report on simulations conducted using the Mbtrack2 code for the 5GeV EIC Electron Storage Ring (ESR) RF system with a reversed phasing scheme. The Mbtrack2 code [1] has been thoroughly benchmarked, as described in references [2] and [3]. The simulation results presented in this paper include the beam loading effect but do not incorporate a feedback system.

43 PARTICLE ACCELERATORS↗