Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Thermal Design”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

Final analysis and design of a thermal protection system for 8-foot HTST combustor

The cylindrical shell combustor with T-bar supports in the 8-foot HTST at the NASA-Langley Research Center encountered vibratory fatigue cracking over a period of 50-250 tunnel tests within a limited range of the required operating envelope. A preliminary design study provided several suitable thermal protection system designs for the combustor, one of which was a two-pass regenerative type air-cooled omega-shaped segment liner. A final design layout of the omega segment liner was prepared and analyzed for steady-state and transient conditions. The design of a support system for the fuel spray bar assembly was also included. Detail drawings suitable for fabrication purposes were also prepared. Liner design problems defined during the preliminary study included (1) the ingress of gas into the attachment bulb section of the omega segment, (2) the large thermal gradient along the leg of the omega bulb attachment section and, (3) the local peak metal temperature at the radius between the liner ID and the leg of the bulb attachment. These were resolved during the final design task. Analyses of the final design of the omega segment liner indicated that all design goals were met and the design provided the capability of operating over the required test envelope with a life expectancy substantially above the goal of 1500 cycles.

Moskowitz, S.↗
DOE OSTI2023

Preliminary Conceptual Design of Nuclear Thermal Rocket Reactor Cores Using Ceramic Fuels with Beryllium or Composite Neutron Moderators

Herein several preliminary conceptual designs of nuclear thermal rocket reactor cores are presented that use tin-bonded monolithic ceramic [mononitride (UN), monocarbide (UC), and uranium dioxide (UO 2 )] fuel plates or pins with molybdenum-tungsten alloy clad. Neutron moderation is provided by a block of Be metal or composite materials using metal hydrides such as ZrH 1.6 or YH 1.6 with different matrices (MgO or Be). Mainly high-assay low-enriched uranium is considered, but highly enriched uranium is also assessed for a few configurations. Nominal core thermal power is 300 MW corresponding to about 66 kN (15 klbf) of thrust, and with minimal modifications, 500 MW may be possible (25 klbf of thrust). Depending on the configurations, the amount of 235 U needed for criticality is 30 to 90 kg, and reactor weight is 2.5 to 3.8 tonnes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Barrier-free predictions of short-range ordering/clustering kinetics in binary FCC solid solutions

We present comparisons of kinetic Monte Carlo (kMC) simulations of isothermal short-range ordering (SRO) and clustering (SRC) kinetics in binary FCC alloys with a mean-field concentration wave (CW) model. We find that the CW model is able to give order-of-magnitude agreement with kMC simulations for ordering/clustering relaxation times over a wide range of temperatures and compositions. The advantage of the CW model is that it does not require parameterization of vacancy hopping energy barriers, which, for a concentrated alloy, becomes prohibitive. We assess limits in the accuracy of the model and discuss the effect of cooling rates as well as the extension to multi-component systems. Ultimately, the simplicity and performance of the CW model compared to kMC simulations suggests that it is a useful tool to connect with models of properties dependent on SRO/SRC as well as for designing thermal treatments to control formation of SRO/SRC.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Novel PtNi single-atom–nanocluster (SA–NC) ensembles promote Tafel kinetics and ampere-class AEM hydrogen evolution

The development of efficient, durable, and low-PGM electrocatalysts for the hydrogen evolution reaction (HER) in alkaline media is critical for next-generation electrolysis technologies. We report a facile two-step synthesis of highly dispersed PtNi and PtNi-nitride nanoclusters (NCs) (~2.3 nm) with ultralow Pt content (0.5 at.%) anchored on N-doped Vulcan carbon. Structural and compositional characterization via XAS, XPS, HAADF-STEM, HRTEM, and EDS mapping established key structure–activity relationships across varying Pt/Ni ratios and pyrolysis temperatures. The Pt0.5Ni0.5/C-750 catalyst, an ensemble of PtNi M-N-C type single-atom (SA) moieties with neighboring PtNi nanoclusters (NC), exhibited superior HER performance in alkaline media, achieving overpotentials of 30, 115, and 210 mV at 10, 100, and 500 mA cm−2, respectively. Despite at a lower Pt content, this novel SA–NC ensemble outperformed commercial Pt/C by ~36%. A standardized literature comparison with contemporary Pt- and Ru-doped analogues reveals the as-prepared Pt0.5Ni0.5/C-750 to sit at the apex of Tafel-limited kinetics and low overpotential at 100 mA cm−2. Tafel-limited Tafel slopes in both alkaline and acidic regimes confirm favorable proton recombination kinetics. Mass activities at 200 mV reached 13.8 and 18.84 A mgPt−1 in alkaline and acidic media, respectively. However, excessive nitridation (e.g., at 650 °C) adversely altered Pt electronic structure and HER kinetics. While Ni enhanced alkaline HER, acidic HER favored Ni-free analogues. Pt0.5Ni0.5/C-750 also demonstrated robust temperature responsiveness and 300-h operational stability at high current densities (0.5–1.0 A cm−2) in MEA tests. This work presents a scalable strategy for designing thermally responsive, durable, and compositionally tunable NC catalysts with neighboring SA moieties for alkaline electrolysis.

AEMWE↗
DOE OSTI2025

Empirically-calibrated H100 node power models for accurate AI training energy estimation

Accurately quantifying the energy use of artificial intelligence (AI) training is critical for infrastructure planning, carbon accounting, and sustainable data center operation, but few studies have directly measured the power consumption of production workloads on contemporary hardware. By combining empirical measurements from Brookhaven National Laboratory during AI training on 8-graphics-processing-unit H100 systems with open-source benchmarking data, we develop statistical models relating computational intensity to node-level power consumption. We measure the gap between manufacturer-rated thermal design power (TDP) and actual power demand during AI training. Our analysis reveals that even computationally intensive workloads operate at only 76% of the 10.2 kW TDP rating. Our architecture-specific model, calibrated to floating-point operations, predicts energy consumption with 11.4% mean absolute percentage error, significantly outperforming TDP-based approaches (27%–37% error). We identified distinct power signatures between transformer and convolutional neural network architectures, with transformers showing characteristic fluctuations that may impact grid stability. These results provide a measurement-grounded basis for improving AI training energy estimates, enabling more reliable infrastructure sizing, cost projections, and environmental impact assessments.

Newkirk, Alex C↗
DOE OSTI2026

Toward Energy-Efficient HPC: Insights from Power Profiling a Cloud-Resolving Earth System Model

Power is a fundamental constraint as supercomputing advances to exascale. Efficient operation within strict power budgets requires application-aware power management based on a detailed understanding of application-level power behavior. This work analyzes the Energy Exascale Earth System Model (E3SM) atmosphere component, SCREAM, on Perlmutter (NERSC) and Frontier (OLCF). We characterize power variation across inputs, concurrency levels, and power caps, evaluate the energy impact of code optimizations, and attribute energy within the code using a newly developed GPU energy model. Results show that SCREAM’s peak power remains stable during its core execution phase and decreases gradually as concurrency increases. Power capping experiments reveal a performance–energy "sweet spot". On Perlmutter, limiting GPU power to 50% of thermal design power (TDP) achieves up to 15% energy savings with a 7% performance penalty. On Frontier, a 40% TDP cap yields up to 10% energy savings with less than 10% performance loss. Code optimizations reduce SCREAM energy by shortening run time without increasing power. Modeling reveals a critical insight: data movement accounts for approximately 70% of SCREAM’s GPU energy. This fundamentally shifts the optimization focus from FLOPS to data transfer reduction for this class of applications, offering the most impactful strategy for improving energy efficiency. This work establishes a foundation for practical, application-aware power management at exascale.

Zhao, Zhengji [Lawrence Berkeley National Laborato↗
DOE OSTI2023

Operando Temperature Measurements of Photovoltaic Laser Power Converter Devices Under Continuous High-Intensity Illumination

Photovoltaic devices that operate under extremely high irradiances, such as laser power converters (LPCs), may also operate at elevated temperatures, even under active cooling, as the result of large temperature gradients. We demonstrate the operation of GaAs LPC devices under orders of magnitude of irradiances up to 150 W/cm 2 in a monochromatic laser simulator with an active cooling stage. The steady-state open-circuit voltage (V OC ) as a function of irradiance is known to droop at high irradiance as the result of junction heating, but the junction temperature can be difficult to measure by conventional methods. Fast, transient V OC measurements under these extreme operating conditions are used here to determine the junction temperature. Empirical V OC temperature coefficients of the devices at each irradiance of interest are determined and used as an integral part of this technique. We show that the thermal design of different LPC devices strongly affects the operating temperature of the junctions. Knowledge of the operating temperature can be a strong tool for understanding the nature of loss mechanisms and improving the design for the operation of photovoltaic LPCs at high irradiances. Furthermore, this technique can be used for laboratory devices during initial design as well as to characterize mass-produced and packaged devices for quality control.

14 SOLAR ENERGY↗
DOE OSTI2024

Advancing Sustainability in Data Centers: Evaluation of Hybrid Air/Liquid Cooling Schemes for IT Payload Using Sea Water

Abstract-The growth in cloud computing, Big Data, AI and high-performance computing (HPC) necessitate the deployment of additional data centers (DC's) with high energy demands. The unprecedented increase in the Thermal Design Power (TDP) of the computing chips will require innovative cooling techniques. Furthermore, DC's are increasingly limited in their ability to add powerful GPU servers by power capacity constraints. As cooling energy use accounts for up to 40% of DC energy consumption, creative cooling solutions are urgently needed to allow deployment of additional servers, enhance sustainability and increase energy efficiency of DC's. The information in this study is provided from Start Campus' Sines facility supported by Alfa Laval for the heat exchanger and CO 2 emission calculations. The study evaluates the performance and sustainability impact of various data center cooling strategies including an air-only deployment and a subsequent hybrid air/water cooling solution all utilizing sea water as the cooling source. Here we evaluate scenarios from 3 MW to 15+1 MW of IT load in 3 MW increments which correspond to the size of heat exchangers used in the Start Campus' modular system design. This study also evaluates the CO 2 emissions compared to a conventional chiller system for all the presented scenarios. Results indicate that the effective use of the sea water cooled system combined with liquid cooled systems improve the efficiency of the DC, plays a role in decreasing the CO 2 emissions and supports in achieving sustainability goals.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Laminated Permanent Magnets Enable Compact Magnetic Components in Current-Source Converters

Magnetic components have become one of the primary barriers to high power density converters, especially to current-source converters (CSCs). In CSCs, the inductors/transformers have a predominantly dc flux to store energy, which can be offset by standard permanent magnets (PMs). However, eddy currents in standard PMs induce significant losses and thermal stress for medium-frequency applications. This article proposes using laminated PMs to offset the dc flux while reducing eddy currents, leading to significant reductions in the size, cost, and losses of inductors/transformers. Furthermore, the laminated PMs’ optimal location, orientation, and distribution are investigated to generalize this approach for maximum benefits. Here, three-dimensional finite-element analysis simulation and hardware experiments are presented to validate the effectiveness of the proposed approach in a medium-frequency transformer (MFT) for CSCs. Compared with standard PMs, the proposed use of laminated PMs reduces aggregate core-plus-PM losses by 85% in experiments, and thus, relaxes the MFT thermal design. Finally, the proposed approach is experimentally validated in a 40 kVA flyback-type MFT for a soft-switching solid-state transformer. Compared to the traditional design without any PMs, the proposed design increases the saturation current by 46% while inducing only 5% more losses, leading to significant savings in magnetics cost and size.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

A Global Perspective on Supercomputer Power Provisioning: Case Studies from United States and Europe

Electrical provisioning in high performance computing is transitioning from simple nameplate Thermal Design Power (TDP) models to more nuanced approaches based on expected electrical load. This paper captures current power provisioning strategies across six international supercomputing centers and seven systems, three of which (Lumi, Summit, Sierra) were in the top 10 of the Top500 list at the time of data collection1. We present longitudinal and summary data of actual power consumption as well as a discussion of how each site approached the question of provisioning. We conclude with a discussion on future directions of hardware overprovisioning and its implications for machine and electrical utilization.

Patki, Tapasya [Lawrence Livermore National Labora↗
DOE OSTI2025

Understanding power and energy utilization in large scale production physics simulation codes

Power is an often-cited reason for the move to advanced architectures on the path to Exascale computing. Here, this is due to practical considerations related to delivering enough power to successfully site and operate these machines, as well as concerns about energy usage while running large simulations. Since obtaining accurate power measurements can be challenging, it may be tempting to use the processor thermal design power (TDP) as a surrogate due to its simplicity and availability. However, TDP is not indicative of typical power usage while running simulations. Using commodity and advanced technology systems at Lawrence Livermore and Sandia National Labs, we performed a series of experiments to measure power and energy usage in running simulation codes. These experiments indicate that large scale Lawrence Livermore simulation codes are significantly more efficient than a simple processor TDP model might suggest.

HPC↗
DOE OSTI2022

Understanding Power and Energy Utilization in Large Scale Production Physics Simulation Codes

Power is an often-cited reason for moving to advanced architectures on the path to Exascale computing. This is due to the practical concern of delivering enough power to successfully site and operate these machines, as well as concerns over energy usage while running large simulations. Since accurate power measurements can be difficult to obtain, processor thermal design power (TDP) is a possible surrogate due to its simplicity and availability. However, TDP is not indicative of typical power usage while running simulations. Using commodity and advance technology systems at Lawrence Livermore National Laboratory (LLNL) and Sandia National Laboratory, we performed a series of experiments to measure power and energy usage in running simulation codes. These experiments indicate that large scale LLNL simulation codes are significantly more efficient than a simple processor TDP model might suggest.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Field Validation of Innovative Air-Source Heat Pumps for Cold-Climate Heating Applications

Air-source heat pumps (ASHPs) have historically found application in milder climates in the United States (US). Their application in cold climates has been hindered by reduced performance as outdoor temperatures fall below freezing and the need for backup or auxiliary electric resistance heaters to meet peak heating loads. Recent advances in cold-climate air-source heat pumps (ccASHPs) with features such as variable-speed compressors, multistage systems, and highly optimized thermal design have improved performance by increasing the coefficient of performance (COP), low-ambient-temperature capacity, and heating seasonal performance factor (HSPF) dramatically. Despite their benefits, ccASHPs are still not widely prescribed for cold climate conditions. This is due in part to a lack of verified, demonstrated performance and analysis in cold climates. Ultimately, high-efficiency ccASHPs play a key role in emerging energy/grid renovation efforts in addition to their potential energy savings and avoided carbon emissions, but their actual performance in various cold climate field settings must be better understood. The primary objective of this project was to measure the in-field performance of variable-capacity air-source heat pumps in cold climates with the goal of enabling the development of field-based performance maps. Specifically, the study looked at how the heat pumps operated in the field, the frequency of cycling, the frequency of defrost events, and the time spent in each mode of operation. The results are intended to be used by DOE to inform research and development of energy-efficient equipment and to develop guidelines for optimizing primary energy savings when using air-source heat pumps in heating-dominated regions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Conceptual Designs for Irradiation Creep Testing of SiC in HFIR

Understanding irradiation creep of nuclear fuel cladding is important to properly size the initial fuel-cladding gap and understand when pellet-cladding contact is expected to occur due to a combination of fuel swelling and cladding creep-down. Irradiation creep also plays a role in relaxing stresses that develop in-pile. Silicon carbide fiber–reinforced silicon carbide matrix (SiC/SiC) composites are the leading long-term accident-tolerant fuel cladding concept for light-water reactors (LWRs). Although some limited data are available regarding irradiation creep of the individual constituents (fibers, matrix), data regarding irradiation creep of SiC/SiC composites are currently insufficient. Additional data regarding irradiation creep compliance and the rupture lifetime (combination of creep and slow crack growth) are needed to understand material limitations. This work describes the design and development of two irradiation vehicles that are being pursued for testing SiC/SiC concepts in the High Flux Isotope Reactor (HFIR). The first is a passive experiment, referred to as the PRECISE experiment, that leverages the constant coolant pressure of HFIR to compress a metallic bellows and provide a well-characterized load to drive creep in a SiC/SiC dog bone specimen. The total creep strain would be quantified post-irradiation by measuring dimensional changes of the specimen length as well as local dimensional changes within the gauge region. Non-stressed specimens would also be irradiated under the same conditions to provide an indication of dimensional changes due to radiation-induced swelling in the absence of creep. A second, more complex experiment, referred to as the INSITE experiment, is being designed in parallel that would use pneumatics to pressurize a metal bellows and linear variable differential transformers (LVDTs) to measure the specimen displacement in situ during irradiation. Such an experiment would provide significantly more data regarding the evolution of the creep compliance as a function of dose and applied stress within a single experiment but would require significantly more development time and cost to execute. The primary concern with the INSITE experiment is the accuracy, reliability, and expected lifetime of the LVDTs during irradiation at elevated temperatures. Efforts are being made to adjust the experiment design and operating procedure to limit LVDT temperatures and mitigate or otherwise compensate for uncertainties due to factors such as temperature fluctuations, creep in the surrounding structural materials, and drift of the LVDTs. This work describes the experiment designs, thermal and structural analysis that were performed to ensure that the desired temperature and stress conditions can be achieved, some initial sensitivity analyses to predict the evolution of the radiation-induced specimen displacements, and potential sources of uncertainty in the measurements. Out-of-pile testing is being performed in parallel to confirm that the test trains achieve the expected stress states in the specimens and do not result in prohibitive stress concentrators (e.g., in the grip regions) that might risk pre-mature failure. The PRECISE experiments are proceeding toward fabrication and assembly with HFIR insertion planned during fiscal year 2026. The INSITE experiment is progressing toward out-of-pile demonstrations, which will provide more conclusive evidence regarding the feasibility of executing these tests in HFIR or whether alternative displacement monitoring techniques may need to be considered.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗