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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 613 records · Page 34

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and facesheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Damage↗

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗

A non-volatile thermal switch for building energy savings

Compared with traditional static insulation, a thermally switchable building envelope could reduce annual heating and cooling loads by intermittently coupling to the outside environment when beneficial. Here, we demonstrate a voltage-actuated, contact/non-contact thermal switch that meets the unique challenges of this application. The switch is non-volatile, consuming electricity only briefly while switching and none to hold steady state. The switch ratio is 12, the off state has a low effective thermal conductivity of 0.045 W m -1 K -1 , comparable to fiberglass insulation, and the performance is stable over 1,000 switching cycles. Numerical simulations using real-world climate data show that combining this thermal switch with a thermal storage layer in a building envelope can yield annual energy savings of 9%-55% (heating) and 17%-76% (air conditioning), depending on the climate zone. The greatest benefits are realized when the exterior temperature crosses well above and below the desired interior temperature within a single 24 h period.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Experimental Characterization of Non-Associative Plasticity Flow Rule Coefficients and Post-Peak Stress Degradation for the LS-DYNA MAT213 Model

This project is focused on developing an experimental framework for characterizing non-associative plasticity flow rule coefficients through coupon-scale tests for the LS-DYNA MAT213 model. The main objective is to characterize these coefficients based on the multi-scale (i.e., both microscopic and macroscopic) full-field measurement of the evolution of strain and stress fields. This paper focuses on presenting the experimental work on characterizing the full-scale stress-strain curves of T700/LM-PAEK composites under tension, compression, and shear loads. The experimental data set was intended to build a deformation sub-model in the MAT213 model for the material. The strain data were collected using both microscopic and macroscopic digital image correlation techniques. The microscopic technique was particularly useful for fracture cases under small strains. A preliminary simulation result obtained from the MAT213 model is also presented in the paper. The experimental framework herein will be extended to characterize post-peak stress degradation in the composite material and to develop a damage sub-model for the material. This project will contribute to developing a simulation tool based on the MAT213 model for simulating the rate-dependent impact damage in composites under multi-axial loading.

MAT213↗

Dual Purpose – Heating & Cooling – Thermal Battery for Flexible and Energy-Efficient Heat Pump Systems

The integration of heat pumps with thermal energy storage (HP-TES) systems is gaining attention as a viable solution for managing peak building demand driven by immense cooling and heating loads. With growing reliance on renewable energy sources, thermal energy storage offers an excellent opportunity to mitigate mismatches in thermal load between energy supply and demand. The use of phase-change material (PCM) TES is especially promising, as PCMs offer significant latent energy storage capacity with smaller temperature glides in smaller volumes compared to other TES technologies. However, challenges arise because current HP-TES architectures can load-shift only cooling or heating, not both, requiring two systems and thus doubling cost, weight, and footprint. Furthermore, current research efforts lack specific tools and techniques to advance integrated systems from concept design to end-user application, focusing on only discharge performance. To address these challenges, this research proposes a dual-mode (heating and cooling) integrated HP-TES system that uses room-temperature PCM-TES as a high-temperature heat source in heating mode and a low-temperature heat sink in cooling mode, thereby reducing temperature lifts and compressor power. Design criteria for PCM-TES heat exchangers were developed, balancing thermal-hydraulic performance with practical constraints such as available building space and weight requirements along with PCM selection considerations such as shipping conditions, moisture exposure, and number of available cycles. A detailed transient model for HP-TES systems was developed to enable rapid annual performance assessments in any US climate zone.

42 ENGINEERING↗

Proactive Regulatory Approaches to Electrification and Load Growth: Workshop Report

On July 10 and 11, 2024, Pacific Northwest National Laboratory and RMI led a workshop in Aurora, Colorado, to explore novel and proactive approaches to electrification and load growth while minimizing risks and costs to customers. Over the next decade, a unique opportunity exists to invest strategically in the electricity system to enable electrification across the transportation, industrial, and building sectors and respond to data and technology-based load growth. However, current utility and regulatory planning practices are insufficient to identify and enable the right investments, and work must be done to reduce the risk and decisional uncertainty faced by utility regulatory commissions and utilities. Ensuring timely electrification investments may require new approaches to address risk, uncertainty, prudence, and cost recovery. Understanding the decision-making process and information needs of utilities and regulators is critical. New policies (or application of policies), financial tools, systems analysis, regulatory mechanisms, and enhanced process transparency may be required. The workshop's goal was to identify proactive regulatory approaches for electrification and load growth that minimize costs and risks to customers. Our intention was that the conversations and the resulting solutions and takeaways would be specific and tactical rather than general and theoretical and that together we would create actionable next steps for key actors in the system, including utilities, regulators, thought leaders, researchers, and the U.S. Department of Energy (DOE). This report is intended to provide workshop attendees with a record and summary of the discussion and proposals raised at the workshop and to provide interested entities who did not attend, such as other regulators, policymakers, utilities, and U.S. DOE offices, with an understanding of what was discussed and with ideas to explore in their organizations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Low Carbon Technology Strategies: Small Office

This document includes steps that building owners and operators can implement to achieve smart, healthy, and low-carbon small office buildings within their existing building portfolios. Small offices are typically less than 50,000 square feet and often use packaged rooftop units for heating, cooling, and ventilation.

analytics↗

Electrical and Thermal Load Impacts of Three District Heating and Cooling Designs for an Existing Community in Washington, DC

District energy systems that provide building heating and cooling are a promising option to provide low-cost, energy efficient heating and cooling solutions for communities. As some buildings move to electrified heating designs, there may be significant increases in electric grid demand, particularly in the winter. District energy systems may be able to help reduce these high electrical demands on the electric grid, while also providing decreased overall energy consumption with an increased flexibility in electrical energy usage. To evaluate and compare district options for district-based heating and cooling, an existing neighborhood of Washington, DC consisting of 35 existing buildings was selected as a case study. This study models and compares a fourth generation (4G) district heating and cooling systems that provide hot and chilled water from a central plant directly to each prosumer and a fifth generation (5G) district heating and cooling systems that provide near-ambient water via geothermal boreholes to interface with an energy transfer station with a heat pump at each prosumer. These district systems are compared against a baseline of the non-connected buildings with their self-contained and current HVAC systems. The neighborhood was selected as a good candidate for a district system for its diversity of loads (mix of different commercial and property types) and the availability of building characteristics. URBANopt District Energy Systems (DES) was used to model the buildings and create initial Modelica models for the district systems. Finally, the DES models were tuned and simulated in Dymola, and the outputs were post-processed for verification and to calculate the electrical and thermal grid impact metrics. This is the first documentation of this workflow and its complete analysis. The three designed systems are compared via their grid metrics including: total energy consumption, electrical demand peak loads, daily peak-to-valley ratios, and system ramping. A detailed discussion is provided about how each system impacts and interacts with the electric grid.

15 GEOTHERMAL ENERGY↗

Testing of a Stitched Composite Large-Scale Multi-Bay Pressure Box

NASA has created the Environmentally Responsible Aviation (ERA) Project to develop technologies to reduce aviation's impact on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe to enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company have worked together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composite structures. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together. The PRSEUS concept is designed to maintain residual load carrying capabilities under a variety of damage scenarios. A series of building block tests were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. The final step in the building block series is an 80%-scale pressure box representing a portion of the center section of a Hybrid Wing Body (HWB) transport aircraft. The testing of this article under maneuver load and internal pressure load conditions is the subject of this paper. The experimental evaluation of this article, along with the other building block tests and the accompanying analyses, has demonstrated the viability of a PRSEUS center body for the HWB vehicle. Additionally, much of the development effort is also applicable to traditional tube-and-wing aircraft, advanced aircraft configurations, and other structures where weight and through-the-thickness strength are design considerations.

Jegley, Dawn↗

Effects of scale in predicting global structural response

Analytical techniques for scale-up effects were reviewed. The advantages and limitations of applying the principles of similitude to composite structures is summarized and illustrated by simple examples. An analytical procedure was formulated to design scale models of an axially compressed composite cylinder. A building-block approach was outlined where each structural detail is analyzed independently and the probable failure sequence of a selected component is predicted, taking into account load redistribution subsequent to first element failure. Details of this building-block approach are under development.

Deo, R. B.↗

Cross-cutting strategies to lower electricity use of miscellaneous electric loads in the domestic sector

Miscellaneous Electric Loads (MELs) account for roughly one quarter of building electricity use in most developed countries. A product-specific approach to lowering MELs electricity use in this category takes too long and costs too much because there are so many MELs, each providing unique services. An alternative approach focusing on key functionalities was therefore explored. These functionalities include: (1) power management, (2) power scaling, and (3) power conversion. Cross-cutting efficiency improvements to these functionalities can be incorporated into broad categories of MELs, thus saving electricity and lowering costs. Even though the population of MELs is diverse and rapidly evolving, major technical opportunities exist to improve their efficiency in these functionalities. Research into energy-saving solutions within the cross-cutting technologies will probably have larger savings than focusing on single products.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of a simplified calibrated building simulation model of a supermarket for proposed ECMs and control strategies impact evaluation

Calibrated building energy simulation is an important pathway to more energy-efficient buildings, but the information requirements of some approaches to this problem are significant. This is particularly true for supermarkets and other so-called “big-box” retail stores. Another characteristic of supermarkets is the significant interaction between Heating Ventilating and Air Conditioning (HVAC) and refrigeration systems in these buildings. These buildings could contain a wide variety of systems and a degree of load diversity that makes calibrated modeling a challenge. This paper describes a simplified approach that uses OpenStudio and EnergyPlus to combine known building parameters with “typical” parameters, resulting in a simplified building that is amenable to calibration. This approach was applied to a big-box store located in Nashville, Tennessee, and a calibrated model was obtained that was used to study potential energy conservation measures. Further, the paper also explores the capabilities of whole-building energy modeling tools, such as EnergyPlus, for modeling the HVAC controls and sequences and their impact evaluation. Although some measures are precluded by the model simplicity, several measures were found to improve the efficiency of the model and demonstrate that the simplified modeling approach is effective. Practical Application: This paper introduces a hybrid approach of building energy model calibration using limited information available from the actual building in combination with characteristics of a “typical” building of the same type. This hybrid approach would also be applicable for other building types than discussed in this paper to calibrate the building energy model using limited information from the actual building.

42 ENGINEERING↗

Grid-interactive Efficient Buildings Projects Summary

Through its grid-interactive efficient building (GEB) research, DOE’s Building Technologies Office seeks to build on existing energy-efficiency efforts to optimize the interplay among energy efficiency, demand response, behind-the-meter generation and energy storage to increase the flexibility of demand-side management. BTO envisions a future where buildings dynamically operate as part of a low cost, reliable electricity grid while meeting the needs and expectations of building occupants.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Open-Source High-Fidelity Aggregate Composite Load Models of Emerging Load Behaviors for Large-Sale Analysis

The goal of this project is to accurately model the dynamic loads for power system planning and operation and to address the challenges inherent in such modeling. Existing load models are inadequate to handle the increasing proliferation of residential air conditioner loads and distributed energy resources, the emerging trends of price-responsive demand, and the growing importance of protective devices in equipment and buildings. A need has emerged to develop a fundamentally new class of load models and next-generation data tools. This work proposes to develop a set of regional–level, scalable open source load models and tools, including large-scale aggregate load protection, concept of price responsive demand, advanced load composition data, next-generation load model data tools, and advanced composite load model calibration and validation frameworks to address new challenges in the representation of next-generation load models.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Community Geothermal: Energy, Cost, and Carbon Modeling for District Design - Ann Arbor, MI

This data includes results on an analysis of existing and projected energy, cost, and carbon for the City of Ann Arbor - District Geothermal Design and Deployment to Equitably Decarbonize Low Income Neighborhoods in Ann Arbor project. The scope of the project includes designing and implementing a geothermal district heating and cooling system that reduces thermal heating and cooling load by 75% and greenhouse gas emissions by 40% in the project area (262 households, 6 commercial buildings). The existing neighborhood was modeled using Design Builder, an EnergyPlus software, to understand the current energy load. The energy model was then flipped to reflect the designed district geothermal heating and cooling system to project the effect on energy, carbon, and cost. This dataset includes the analysis files utilized and created for this study. There are 3 categories of data: 1) existing/benchmarking, 2) energy modeling, and 3) post processed calculations. This follows the methodology and process of the project team, which is fully explained in file 00_Technical Economic Environmental Assessment. All uses of data are referenced throughout this assessment to their respective files included below.

15 GEOTHERMAL ENERGY↗

Practical challenges of model predictive control (MPC) for grid interactive small and medium commercial buildings

To the urgent call for mitigating climate change, substantial initiatives have been undertaken to deploy grid-interactive heating, ventilation, and air-conditioning (HVAC) controls, such as model predictive control (MPC) for buildings. These efforts typically aim to curtail peak energy demand, shift load and enhance overall energy efficiency. With the recent development of low-cost MPC technologies that don’t require extensive instrumentation or manual modeling, small and medium commercial buildings (SMCBs), which rarely utilize advanced HVAC control systems, have become candidates for grid-interactive efficient buildings (GEBs). However, despite the potential benefits and maturity of the technology itself, several practical challenges remain in real-world implementation. In this paper, we share the practical challenges that we have encountered in implementing and testing three types of MPC solutions (ON/OFF unit, dualfuel, and VRF systems) on multiple SMCB sites. We describe the MPC deployment process and discuss the lessons learned. The site selection, eligibility, and retrofit availability (e.g., utility price structure, thermostat communications, etc.) are the main discussion points at the beginning of the project. Also, the modeling automation and the best practices for interacting with endusers and handling erroneous situations are presented for successful operations.

woo Ham, Sang↗

Assessing uncertainty in the timing of energy use during cost-optimal distributed energy technology selection and sizing

This paper empirically derives uncertainty ranges in cost-optimal solar PV and storage sizing by comparing results from the REopt Lite optimization platform from metered data and a set of simulated Department of Energy Commercial Reference Building (CRB) profiles at 65 sites. We find load profile shape alone does not explain a site’s optimal configurations (i.e., PV, Storage, PV and Storage, No System). Still, load profile shape does introduce uncertainty to optimal PV and storage capacities. Across all cases where PV is part of an optimal configuration, we find the average ratio of power capacities derived from metered loads to capacities derived from CRB profiles to be 0.97 (and as high as 1463), where 1 would be a perfect match in system size. For storage, the ratio is 1.6 (and as high as 42). We also assess how, in the absence of complete metered data, a CRB profile can be selected that would be expected to yield the most similar solar PV and storage capacities. From those metrics that can be available from billing data (i.e., peak demand, monthly load totals), we find that uncertainty is most reduced by selecting the CRB’s with an annual peak occurring at the most similar time, or those with the lowest average root mean square error (RMSE) among monthly peak loads. This research can help improve the implementation and interpretation of results derived from simulated load profiles and is an important next step in advancing smart grid solutions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

OpenStudio System-level KPI Reporting Measure v1.0

This is a OpenStudio measure that calculates and reports the system-level key performance indicators (KPIs) for evaluating building energy performance at the system level. The systems are defined by the service it provides in commercial buildings, which include (1) lighting, (2) Miscellaneous Electric Loads (MELs), (3) Heating, Ventilation and Air Conditioning (HVAC), and (4) Service Water Heating (SWH).

Li, Han↗