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DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗

NASA NTRS2012

Experimental Studies of Carbon Nanotube Materials for Space Radiators

Game ]changing propulsion systems are often enabled by novel designs using advanced materials. Radiator performance dictates power output for nuclear electric propulsion (NEP) systems. Carbon nanotubes (CNT) and carbon fiber materials have the potential to offer significant improvements in thermal conductivity and mass properties. A test apparatus was developed to test advanced radiator designs. This test apparatus uses a resistance heater inside a graphite tube. Metallic tubes can be slipped over the graphite tube to simulate a heat pipe. Several sub ]scale test articles were fabricated using CNT cloth and pitch ]based carbon fibers, which were bonded to a metallic tube using an active braze material. The test articles were heated up to 600 C and an infrared (IR) camera captured the results. The test apparatus and experimental results are presented here.

SanSoucie, MIchael P.↗

DOE OSTI2024

Non-contact Real-time Target Health Monitor

Targets are an essential part of many accelerator-based experiments, yet their constant radiation exposure eventually affects their internal structure and, consequently, their properties. Current methods typically involve either direct contact with the target or complete removal of the system, which may not be the most efficient for assessing radiation damage. For this reason, a system has been proposed that will monitor a target s radiation damage without the need for direct contact or removal. This sensor will achieve this by measuring the reflectivity of S- and P-polarized waves, which are expected to change measurably due to radiation-induced alterations. As is commonly done, smaller-scale tests were performed to ensure that the necessary equipment was functioning correctly. Once all equipment is tested, the next step will be to perform reflectivity measurements using a tungsten sample, a material often used in targets. Longer-term work will involve scaling up the system and implementing higher-energy beams. This sensor will enable a more comprehensive study of radiation damage in materials and is being considered for projects such as Mu2e, Mu2e-II, LBNF, AMF, and muon colliders.

Agosto Reyes, Alanice↗

NASA NTRS1975

Evaluation of boron/aluminum tubes in compression

A brief analytical and experimental investigation was conducted to determine the compressive behavior of a limited number of boron/aluminum (B/Al) tubes. The purpose of the investigation was to gain hardware experience in a limited evaluation of the material for possible application to spacecraft truss structures. Specimen description, test procedures and results are presented as well as comparisons with theoretical predictions regarding local column stability. It is shown that the experimental results of full-scale tests are consistent with previously reported data and that the local stability of B/Al columns as determined through short column tests can best be predicted using large deflection theory.

Knoell, A. C.↗

NASA NTRS2015

Advancing the State-of-the-Practice for Liquid Rocket Engine Injector Design

Current shortcomings in both the overall injector design process and its underlying combustion stability assessment methodology are rooted in the use of empirically based or low fidelity representations of complex physical phenomena and geometry details that have first order effects on performance, thermal environments and combustion stability. The result is a design and analysis capability that is often inadequate to reliably arrive at a suitable injector design in an efficient manner. Specifically, combustion instability has been particularly difficult to predict and mitigate. Large hydrocarbon-fueled booster engines have been especially problematic in this regard. Where combustion instability has been a problem, costly and time-consuming redesign efforts have often been an unfortunate consequence. This paper presents an overview of a recently completed effort at NASA Marshall Space Flight Center to advance the state-of-the-practice for liquid rocket engine injector design. Multiple perturbations of a gas-centered swirl coaxial (GCSC) element that burned gaseous oxygen and RP-1 were designed, assessed for combustion stability, and tested. Three designs, one stable, one marginally unstable and one unstable, were used to demonstrate both an enhanced overall injector design process and an improved combustion stability assessment process. High-fidelity results from state-of-the-art computational fluid dynamics CFD simulations were used to substantially augment and improve the injector design methodology. The CFD results were used to inform and guide the overall injector design process. They were also used to upgrade selected empirical or low-dimensional quantities in the ROCket Combustor Interactive Design (ROCCID) stability assessment tool. Hot fire single element injector testing was used to verify both the overall injector designs and the stability assessments. Testing was conducted at the Air Force Research Laboratory and at Purdue University. Companion papers provide details of the overall injector design process, full- and sub-scale testing, ROCCID-based stability assessments and the CFD simulations.

Tucker, P. K.↗

DOE OSTI2025

Transforming Aeration Energy in Water Resource Recovery Facilities (WRRFs) through Suboxic Nitrogen Removal (Final Report)

The objective of this project was to advance two key technological components—aeration control strategies and process design methodologies—to support the development and broader adoption of suboxic biological nitrogen removal (SBNR). The project focused on achieving the following three goals: • Enhance Model Predictive Control (MPC) Technology: Advance the DO/Nmaster MPC platform from its initial 2018 pilot deployment at the Chico Water Resource Recovery Facility in California to full-scale integration. This included partnering with a blower technology commercialization partner and incorporating machine learning (ML) capabilities to enable nationwide deployment. • Bridge Knowledge Gaps in SBNR Process Design: Address fundamental gaps in SBNR process understanding through controlled pilot-scale testing at a dedicated pilot facility. These efforts supported the development of robust kinetic models to inform reliable SBNR control, operational strategies, and design frameworks. • Demonstrate Full-Scale Implementation of Low DO/SBNR with ML: Transition low dissolved oxygen (DO)/SBNR coupled with ML from pilot-scale trials to full-scale demonstration in flow-through biological nutrient removal (BNR) systems, with the goal of enabling scalable, nationwide adoption in activated sludge treatment processes. The project included demonstration of SBNR at the pilot scale as performed by Hampton Roads Sanitation District (HRSD) and at the full-scale as performed by the Los Angeles County Sanitation Districts' (LACSD) Pomona Water Reclamation Plant (POWRP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2006

Latest Developments in SLD Scaling

Scaling methods have been shown previously to work well for super cooled large droplet (SLD) main ice shapes. However, feather sizes for some conditions have not been well represented by scale tests. To determine if there are fundamental differences between the development of feathers for appendix C and SLD conditions, this study used time-sequenced photographs, viewing along the span of the model during icing sprays. An airspeed of 100 kt, cloud water drop MVDs of 30 and 140 microns, and stagnation freezing fractions of 0.30 and 0.50 were tested in the NASA Glenn Icing Research Tunnel using an unswept 91-cm-chord NACA0012 airfoil model mounted at 0deg AOA. The photos indicated that the feathers that developed in a distinct region downstream of the leading-edge ice determined the horn location and angle. The angle at which feathers grew from the surface were also measured; results are shown for an airspeed of 150 kt, an MVD of 30 microns, and stagnation freezing fractions of 0.30 to 0.60. Feather angles were found to depend strongly on the stagnation freezing fraction, and were independent of either chordwise position on the model or time into the spray. Feather angles also correlated well with horn angles. For these tests, there did not appear to be fundamental differences between the physics of SLD and appendix C icing; therefore, for these conditions similarity parameters used for appendix C scaling appear to be valid for SLD scaling as well. Further investigation into the cause for the large feather structures observed for some SLD conditions will continue.

Tsao, Jen-Ching↗

NASA NTRS1947

Comparison of Wind-Tunnel Predictions with Flight Measurements of the Longitudinal-Stability and -Control Characteristics of a Douglas BTD-1 Airplane

Low Mach number longitudinal-stability and control characteristics as predicted by use of wind tunnel data from a powered 3/16-scale model are compared with flight test measurements of a Navy BTD-1 airplane. The accuracy of the wind tunnel data and the discrepancies involved in attempting to correlate with flight data are discussed and analyzed. The comparison showed that wind tunnel predictions were, in general, in good agreement with flight test data. The predicted values were for the most part sufficiently accurate to show the satisfactory and unsatisfactory characteristics in the preliminary design stage and to indicate possible methods of improvement. The discrepancies which did occur were attributed principally to physical dissimilarities between model and airplane and the instability to determine accurately the flight power conditions. The effect of Mach number was considered negligible since the maximum flight test value was about 0.5. In order to simulate more closely the flight conditions and hence obtain more accurate data for predictions, it appears desirable to perform large-scale tests of unorthodox control surfaces such as the sealed vaned elevators with which the airplane was equipped.

Bunnell, Mort V.↗

NASA NTRS1931

The Effect of Reduction Gearing on Propeller-body Interference as Shown by Full-Scale Wind-Tunnel Tests

This report presents the results of full-scale tests made on a 10-foot 5-inch propeller on a geared J-5 engine and also on a similar 8-foot 11-inch propeller on a direct-drive J-5 engine. Each propeller was tested at two different pitch settings, and with a large and a small fuselage. The investigation was made in such a manner that the propeller-body interference factors were isolated, and it was found that, considering this interference only, the geared propellers had an appreciable advantage in propulsive efficiency, partially due to the larger diameter of the propellers with respect to the bodies, and partially because the geared propellers were located farther ahead of the engines and bodies.

Weick, Fred E↗

DOE OSTI2025

Performance-portable Binary Neutron Star Mergers with AthenaK

We introduce an extension to the AthenaK code for general-relativistic magnetohydrodynamics (GRMHD) in dynamical spacetimes using a 3+1 conservative Eulerian formulation. Like the fixed-spacetime GRMHD solver, we use standard finite-volume methods to evolve the fluid and a constrained-transport scheme to preserve the divergence-free constraint for the magnetic field. We also utilize a first-order flux correction (FOFC) scheme to reduce the need for an artificial atmosphere and optionally enforce a maximum principle to improve robustness. We demonstrate the accuracy of AthenaK using a set of standard tests in flat and curved spacetimes. Using a SANE accretion disk around a Kerr black hole, we compare the new solver to the existing solver for stationary spacetimes using the so-called "HARM-like" formulation. We find that both formulations converge to similar results. We also include the first published binary neutron star (BNS) mergers performed on graphical processing units (GPUs). Thanks to the FOFC scheme, our BNS mergers maintain a relative error of $\mathcal{O}$(10 –11 ) or better in baryon mass conservation up to collapse. Finally, we perform scaling tests of AthenaK on OLCF Frontier, where we show excellent weak scaling of ≥80% efficiency up to 32,768 GPUs and 74% up to 65,536 GPUs for a GRMHD problem in dynamical spacetimes with six levels of mesh refinement. AthenaK achieves an order-of-magnitude speedup using GPUs compared to CPUs, demonstrating that it is suitable for performing numerical relativity problems on modern exascale resources.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1978

Full-scale wind tunnel test of a modern helicopter main rotor - Investigation of tip Mach number effects and comparisons of four tip shapes

A test of a full-scale helicopter rotor was conducted in the NASA Ames Research Center 40- by 80-Foot Wind Tunnel to investigate performance characteristics of rotors with various tip geometries. Four blade tip geometries were investigated: rectangular, trapezoidal, swept rectangular, and swept trapezoidal. The investigation was accomplished over an advance ratio range of 0.2 to 0.375 and an advancing blade Mach number range from 0.72 up to 0.97. On a power basis, the best overall tip geometry was the swept trapezoidal configuration.

Stroub, R. H.↗

NASA NTRS2017

NASA's Space Launch System Takes Shape

Significant hardware and software for NASA's Space Launch System (SLS) began rolling off assembly lines in 2016, setting the stage for critical testing in 2017 and the launch of new capability for deep-space human exploration. (Figure 1) At NASA's Michoud Assembly Facility (MAF) near New Orleans, LA, full-scale test articles are being joined by flight hardware. Structural test stands are nearing completion at NASA's Marshall Space Flight Center (MSFC), Huntsville, AL. An SLS booster solid rocket motor underwent test firing, while flight motor segments were cast. An RS-25 and Engine Control Unit (ECU) for early SLS flights were tested at NASA's Stennis Space Center (SSC). The upper stage for the first flight was completed, and NASA completed Preliminary Design Review (PDR) for a new, powerful upper stage. The pace of production and testing is expected to increase in 2017. This paper will discuss the technical and programmatic highlights and challenges of 2016 and look ahead to plans for 2017.

Askins, Bruce R.↗

NASA NTRS1994

Milestone 4: Thrust structure concepts and IHM screening Graphite Composite Primary Structure (GCPS)

The first part of the task was to select up to three promising thrust structure constructions and to select materials for screening tests. Part of the nondestructive evaluation and inspection (NDE/I) and integrated health management (IHM) task is to acquire and develop NDE/I sensor technologies and to integrate those sensors into the full scale test articles which will be produced under the TA2 program. Review of the anticipated fault modes and the available sensor technology data indicates that three sensor technologies should be assessed for the in-situ monitoring of the composite primary structure elements. These are: ultrasonics (dry contact), acoustic emissions, and fiber optics (embedded or attached). In fact, a combination of sensor technologies will be needed to detect and evaluate the fault modes; not only do sensor technology have specific capabilities and applicability, but the three Gr/Ep primary structures being demonstrated under the TA2 effort have differing requirements based on their respective failure modes and designs.

Greenberg, H. S.↗

NASA NTRS2020

Quiet Supersonic Flights 2018 (QSF18) Test: Galveston, Texas Risk Reduction for Future Community Testing with a Low-Boom Flight Demonstration Vehicle

The Quiet Supersonic Flights 2018 (QSF18) Program was designed to develop tools and methods for demonstration of overland supersonic flight with an acceptable sonic boom, and collect a large dataset of responses from a representative sample of the population. Phase 1 provided the basis for a low amplitude sonic boom testing in six different climate regions that will enable international regulatory agencies to draft a noise-based standard for certifying civilian supersonic overland flight. Phase 2 successfully executed a large scale test in Galveston, Texas, developed well documented data sets, calculated dose response relationships, yielded lessons, and identified future risk reduction activities.

Galveston↗

NASA NTRS2020

Quiet Supersonic Flights 2018 (QSF18) Test: Galveston, Texas Risk Reduction for Future Community Testing with a Low-Boom Flight Demonstration Vehicle

Galveston↗

DOE OSTI2023

Deploying Extended Reality (XR) for Digital Operations and Maintenance (O&M) at the Mechanisms Engineering Test Loop (METL)

This report documents the preliminary efforts to digitize operation and maintenance (O&M) activities for the Mechanisms Engineering Test Loop (METL). METL became operational in September 2018 with the mission to provide an ecosystem for Advanced Reactor Development (ARD). METLs flagship facility’s primary purpose is conducting small to intermediate scale tests for Sodium Fast Reactors (SFR). Its resemblance to commercial SFR’s intermediate heat transport system, prototypic operating conditions, and industrial construction practices/materials provides the overarching benefit of establishing a proving ground for emerging operations and maintenance (O&M) activities such as incorporating Extended Reality (XR) applications throughout the program lifecycle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

High-Temperature Sodium System Structural Health Monitoring (SHM) Technologies at the Mechanisms Engineering Test Loop (METL)

This report documents the deployment of non-destructive testing (NDT) technologies at the Mechanisms Engineering Test Loop (METL). METL became operational in September 2018 with the mission to provide an ecosystem for Advanced Reactor Development (ARD). METLs flagship facility’s primary purpose is conducting small to intermediate scale tests for Sodium Fast Reactors (SFR). Its resemblance to a commercial SFR’s intermediate heat transport system, prototypic operating conditions, and industrial construction practices/materials provides the overarching benefit of establishing a proving ground for devices of all technology readiness levels as well as commercial off-the-shelf equipment yet to be demonstrated on a sodium system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2007

Damage Tolerance of Composites

Fracture control requirements have been developed to address damage tolerance of composites for manned space flight hardware. The requirements provide the framework for critical and noncritical hardware assessment and testing. The need for damage threat assessments, impact damage protection plans, and nondestructive evaluation are also addressed. Hardware intended to be damage tolerant have extensive coupon, sub-element, and full-scale testing requirements in-line with the Building Block Approach concept from the MIL-HDBK-17, Department of Defense Composite Materials Handbook.

Hodge, Andy↗