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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

The 2023 Gold Run in the Injectors

RHIC Run 23 used Gold beam from Tandem with an AGS extraction energy of 9.8 GeV. The same basic setup, 8 single bunch transfers from the Booster and a 12-6 merge in the AGS to provide 4 bunches at extraction, had been used before to deliver Tandem Au to RHIC. But in those cases, it was used for low energy runs (3.85 GeV in 2021 and 5.75 GeV in 2020) where extraction was below transition energy (7.9 GeV). Tandem beam was used for this run because the intensity and stability of EBIS Au did not meet the requirements for RHIC. Physics was first declared in RHIC on May 22 nd and on August 1 st the run was cut short by about 2 months due to a major failure in RHIC. Prior to the advent of EBIS as the preinjector in 2012, 9.8 GeV Tandem Au was regularly delivered to RHIC but the setup in the Booster and AGS was quite different: Four Booster transfers of 6 bunches each were merged into 4 bunches using a 24-12-4 merge scheme. The supercycle length was 6.0 sec before June 29 th when it was extended to 6.6 sec to accommodate EBIS commissioning. The Tandem, Booster, and AGS were on user 1 for the 9.8 GeV setup. Some work with EBIS Au 32+ took place on EBIS, Booster, and AGS user 5 using the standard 9.8 GeV injector setup with a 4 to 1 merge in Booster and a 6-3-1 type merge in AGS. The Siemens motor generator was used for the entire run. An intensity limit of 8.0e9 Au 77+ ions in the AGS was in effect during the run to protect the J7 plunging stripping foil and the Copper absorber of the AGS beam dump. This corresponds to a merged bunch intensity limit of 2.0e9 Au 77+ ions for 4 equal intensity bunches. The per bunch intensity limit can be increased to 2.67e9 by reducing the number of BtA transfers from 8 to 6. There was also a Booster Late intensity limit of 16e9 Au ions in effect to protect the BtA stripping foil from damage due to overheating. Lowering the number of transfers also makes this limit less of a constraint. BtA foil 5, which was installed in 2020 and had not been used regularly prior to this run was used all run and showed no obvious signs of deterioration. In May, a Tandem Au 3.85 GeV setup from 2021 was also re-established on AGS user 2. It was used for APEX on May 24 and July 26. Initial work with 3.85 GeV beam was on May 19. Proton beam was also set up during the run and extracted to W dump on July 10. It was used for APEX on July 12. Although the OPPIS source was used the AGS setup was without snakes.

43 PARTICLE ACCELERATORS↗
NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗
NASA NTRS2017

An Initial Study of the Fundamentals of Ice Crystal Icing Physics in the NASA Propulsion Systems Laboratory

This presentation shows results from an initial study of the fundamental physics of ice-crystal ice accretion using the NASA Propulsion Systems Lab (PSL). Ice accretion due to the ingestion of ice-crystals is being attributed to numerous jet-engine power-loss events. The NASA PSL is an altitude jet-engine test facility which has recently added a capability to inject ice particles into the flow. NASA is evaluating whether this facility, in addition to full-engine and motor-driven-rig tests, can be used for more fundamental ice-accretion studies that simulate the different mixed-phase icing conditions along the core flow passage of a turbo-fan engine compressor. The data from such fundamental accretion tests will be used to help develop and validate models of the accretion process. The present study utilized a NACA0012 airfoil. The mixed-phase conditions were generated by partially freezing the liquid-water droplets ejected from the spray bars. This presentation shows data regarding (1) the freeze out characteristics of the cloud, (2) changes in aerothermal conditions due to the presence of the cloud, and (3) the ice accretion characteristics observed on the airfoil model. The primary variable in this test was the PSL plenum humidity which was systematically varied for two duct-exit-plane velocities (85 and 135 ms) as well as two particle size clouds (15 and 50 m MVDi). The observed clouds ranged from fully glaciated to fully liquid, where the liquid clouds were at least partially supercooled. The air total temperature decreased at the test section when the cloud was activated due to evaporation. The ice accretions observed ranged from sharp arrow-like accretions, characteristic of ice-crystal erosion, to cases with double-horn shapes, characteristic of supercooled water accretions.

upwind schemes↗
NASA NTRS2017

An Initial Study of the Fundamentals of Ice Crystal Icing Physics in the Nasa Propulsion Systems Laboratory

This paper presents results from an initial study of the fundamental physics of ice-crystal ice accretion using the NASA Propulsion Systems Lab (PSL). Ice accretion due to the ingestion of ice-crystals is being attributed to numerous jet-engine power-loss events. The NASA PSL is an altitude jet-engine test facility which has recently added a capability to inject ice particles into the flow. NASA is evaluating whether this facility, in addition to full-engine and motor-driven-rig tests, can be used for more fundamental ice-accretion studies that simulate the different mixed-phase icing conditions along the core flow passage of a turbo-fan engine compressor. The data from such fundamental accretion tests will be used to help develop and validate models of the accretion process. The present study utilized a NACA0012 airfoil. The mixed-phase conditions were generated by partially freezing the liquid-water droplets ejected from the spray bars. This paper presents data regarding (1) the freeze out characteristics of the cloud, (2) changes in aerothermal conditions due to the presence of the cloud, and (3) the ice accretion characteristics observed on the airfoil model. The primary variable in this test was the PSL plenum humidity which was systematically varied for two duct-exit-plane velocities (85 and 135 ms) as well as two particle size clouds (15 and 50 m MVDi). The observed clouds ranged from fully glaciated to fully liquid, where the liquid clouds were at least partially supercooled. The air total temperature decreased at the test section when the cloud was activated due to evaporation. The ice accretions observed ranged from sharp arrow-like accretions, characteristic of ice-crystal erosion, to cases with double-horn shapes, characteristic of supercooled water accretions.

Evaporative Cooling↗
NASA NTRS2021

Volatile chemical product emissions enhance ozone and modulate urban chemistry

Decades of air quality improvements have substantially reduced the motor vehicle emissions of volatile organic compounds (VOCs). Today, volatile chemical products (VCPs) are responsible for half of the petrochemical VOCs emitted in major urban areas. We show that VCP emissions are ubiquitous in US and European cities and scale with population density. We report significant VCP emissions for New York City (NYC), including a monoterpene flux of 14.7 to 24.4 kg ⋅ d−1 ⋅ km−2 from fragranced VCPs and other anthropogenic sources, which is comparable to that of a summertime forest. Photochemical modeling of an extreme heat event, with ozone well in excess of US standards, illustrates the significant impact of VCPs on air quality. In the most populated regions of NYC, ozone was sensitive to anthropogenic VOCs (AVOCs), even in the presence of biogenic sources. Within this VOC-sensitive regime, AVOCs contributed upwards of ∼20 ppb to maximum 8-h average ozone. VCPs accounted for more than 50% of this total AVOC contribution. Emissions from fragranced VCPs, including personal care and cleaning products, account for at least 50% of the ozone attributed to VCPs. We show that model simulations of ozone depend foremost on the magnitude of VCP emissions and that the addition of oxygenated VCP chemistry impacts simulations of key atmospheric oxidation products. NYC is a case study for developed megacities, and the impacts of VCPs on local ozone are likely similar for other major urban regions across North America or Europe.

Matthew M. Coggon↗
DOE OSTI2023

Assessment of an E10 gasoline surrogate: Qualitative and quantitative comparisons of in-cylinder spray morphology

A minimum-component gasoline fuel surrogate that captures both chemical and physical behaviors of a full-distillate fuel is needed for high-fidelity CFD simulations. This study evaluates gasoline spray characteristics in a direct-injection spark-ignition engine under motored operation. Two fuels are compared; PACE-20, which is a 9-component surrogate formulation of RD5-87, is compared with its target fuel RD5-87, which is a full-boiling range research grade E10 gasoline. The spray morphologies of both fuels are recorded for a centrally-located direct-injection 8-hole spray subject to intake air cross-flow during the early part of the intake stroke. High-speed imaging recorded scattered light of the side and axial projections of the liquid spray. Quantitative metrics were developed and employed to facilitate comparison of spray morphologies as well as to identify the transition in spray morphology due to flash boiling. This paper builds on a previous study of RD5-87 where coolant temperature (20°C–100°C), in-cylinder pressure (40–110 kPa), engine speed (650–1950 rpm), and injection pressure (60–180 bar) were systematically changed to span operating conditions with and without flash boiling. Images of the PACE-20 morphology are selected for a sub-set of operating conditions from the previous study where distinctive morphology changes occurred. Visual inspection of the images and quantitative metrics demonstrate that the PACE-20 spray morphology is equivalent to that of the RD5-87 in most cases. The exception was for changes in the ambient-gas pressure where the flash-boiling transition occurred at ∼5 kPa higher in-cylinder pressure for PACE-20. Three empirical metrics, Merging Index, Asymmetry, and Flash Index are proposed here and they were found to be useful both as quantitative comparisons of the fuel morphologies, and for identifying the transition in spray morphology due to flash boiling.

Kim, Namho↗
NASA NTRS2012

Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications

The need to maintain optimal energy efficiency is critical during the drilling operations performed on future and current planetary rover missions (see figure). Specifically, this innovation seeks to solve the following problem. Given a spring-loaded percussive drill driven by a voice-coil motor, one needs to determine the optimal input voltage waveform (periodic function) and the optimal hammering period that minimizes the dissipated energy, while ensuring that the hammer-to-rock impacts are made with sufficient (user-defined) impact velocity (or impact energy). To solve this problem, it was first observed that when voice-coil-actuated percussive drills are driven at high power, it is of paramount importance to ensure that the electrical current of the device remains in phase with the velocity of the hammer. Otherwise, negative work is performed and the drill experiences a loss of performance (i.e., reduced impact energy) and an increase in Joule heating (i.e., reduction in energy efficiency). This observation has motivated many drilling products to incorporate the standard bang-bang control approach for driving their percussive drills. However, the bang-bang control approach is significantly less efficient than the optimal energy-efficient control approach solved herein. To obtain this solution, the standard tools of classical optimal control theory were applied. It is worth noting that these tools inherently require the solution of a two-point boundary value problem (TPBVP), i.e., a system of differential equations where half the equations have unknown boundary conditions. Typically, the TPBVP is impossible to solve analytically for high-dimensional dynamic systems. However, for the case of the spring-loaded vibro-impactor, this approach yields the exact optimal control solution as the sum of four analytic functions whose coefficients are determined using a simple, easy-to-implement algorithm. Once the optimal control waveform is determined, it can be used optimally in the context of both open-loop and closed-loop control modes (using standard realtime control hardware).

Aldrich, Jack B.↗
NASA NTRS2013

Method to Increase Performance of Foil Bearings Through Passive Thermal Management

This invention is a new approach to designing foil bearings to increase their load capacity and improve their reliability through passive thermal management. In the present case, the bearing is designed in such a way as to prevent the carryover of lubricant from the exit of one sector to the inlet of the ensuing sector of the foil bearing. When such passive thermal management techniques are used, bearing load capacity is improved by multiples, and reliability is enhanced when compared to current foil bearings. This concept has recently been tested and validated, and shows that load capacity performance of foil bearings can be improved by a factor of two at relatively low speeds with potentially greater relative improvements at higher speeds. Such improvements in performance with respect to speed are typical of foil bearings. Additionally, operation of these newly conceived bearings shows much more reliability and repeatable performance. This trait can be exploited in machine design to enhance safety, reliability, and overall performance. Finally, lower frictional torque has been demonstrated when operating at lower (non-load capacity) loads, thus providing another improvement above the current state of the art. The objective of the invention is to incorporate features into a foil bearing that both enhance passive thermal management and temperature control, while at the same time improve the hydrodynamic (load capacity) performance of the foil bearing. Foil bearings are unique antifriction devices that can utilize the working fluid of a machine as a lubricant (typically air for turbines and motors, liquids for pumps), and as a coolant to remove excess energy due to frictional heating. The current state of the art of foil bearings utilizes forced cooling of the bearing and shaft, which represents poor efficiency and poor reliability. This invention embodies features that utilize the bearing geometry in such a manner as to both support load and provide an inherent and passive cooling mechanism. This cooling mechanism functions in such a way as to prevent used (higher temperature) lubricant from being carried over from the exit of one sector into the entry of the next sector of the foil bearing. The disclosed innovation is an improved foil bearing design that reduces or eliminates the need for force cooling of the bearing, while at the same time improving the load capacity of the bearing by at least a factor of two. These improvements are due to the elimination of lubricant carryover from the trailing edge of one sector into the leading edge of the next, and the mixing of used lubricant with the surrounding ambient fluid.

Bruckner, Robert↗
NASA NTRS2009

T-Rex: A Japanese Space Tether Experiment

Electrodynamic tether (EDT) thrusters work by virtue of the force a magnetic field exerts on a wire carrying an electrical current. The force, which acts on any charged particle moving through a magnetic field (including the electrons moving in a current-carrying wire), were concisely expressed by Lorentz in 1895 in an equation that now bears his name. The force acts in a direction perpendicular to both the direction of current flow and the magnetic field vector. Electric motors make use of this force: a wire loop in a magnetic field is made to rotate by the torque the Lorentz Force exerts on it due to an alternating current in the loop times so as to keep the torque acting in the same sense. The motion of the loop is transmitted to a shaft, thus providing work. Although the working principle of EDT thrusters is not new, its application to space transportation may be significant. In essence, an EDT thruster is just a clever way of getting an electrical current to flow in a long orbiting wire (the tether) so that the Earth s magnetic field will accelerate the wire and, consequently the payload attached to the wire. The direction of current flow in the tether, either toward or away from the Earth along the local vertical, determines whether the magnetic force will raise or lower the orbit. The bias voltage of a vertically deployed metal tether, which results just from its orbital motion (assumed eastward) through Earth s magnetic field, is positive with respect to the ambient plasma at the top and negative at the bottom. This polarization is due to the action of the Lorentz force on the electrons in the tether. Thus, the natural current flow is the result of negative electrons being attracted to the upper end and then returned to the plasma at the lower end. The magnetic force in this case has a component opposite to the direction of motion, and thus leads to a lowering of the orbit and eventually to re-entry. In this generator mode of operation the Lorentz Force serves both to drive the current and then to act on the current to decelerate the system. One of the most important features of tether thrusters is that they use renewable energy sources to drive the electrical current flow in either the orbit-raising or orbit-lowering modes. Sources inherent to Earth orbit are used. To raise the orbit, sunlight can be converted to the electrical energy required to drive the tether current. To lower the orbit, the orbital energy itself (supplied by the Earth-to-orbit launcher when it raises the system into orbit) is the energy source of the tether current via the action of the Lorentz Force. Electrodynamic tethers can be directly applied to a wide spectrum of uses in space. As a propulsion system, they include satellite de-orbit, transfer of a satellite from one orbit to another, altitude maintenance for large spacecraft such as the International Space Station, and since it works wherever there is a magnetic field and an ionosphere planetary exploration missions. An electrodynamic tether upper stage could be used as an Orbit Transfer Vehicle (OTV) to move payloads within low earth orbit. The OTV would rendezvous with the payload and launch vehicle, grapple the payload and maneuver it to a new orbital altitude or inclination without the use of boost propellant. The tug could then lower its orbit to rendezvous with the next payload and repeat the process. Conceivably, such a system could perform several orbital maneuvering assignments without resupply, making it relatively inexpensive to operate.

Johnson, Les↗
DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2011

Diagonal-Axes Stage for Pointing an Optical Communications Transceiver

Traditional azimuth-elevation ("az-el") stages are used to point a variety of devices ranging from large optical telescopes to tank guns. Such a stage typically has an elevation stage having a horizontal axis mounted on an azimuth stage with a vertical axis. Both stages are often motorized. Optical communications transceivers often require two-axis motorized control, as when the communications link is between a ground station and an aircraft or satellite. In such applications, the traditional azimuth-elevation stage has two important drawbacks: a gimbal lock exclusion zone at zenith and susceptibility to pointing errors caused by backlash. Az-el stages in which the azimuth stage cannot rotate a full 360deg have the additional drawback of an azimuth exclusion zone. The diagonal-axes stage described here mitigates or eliminates all of these problems. Instead of one vertical axis and one horizontal axis, a diagonal-axes stage has two horizontal axes, both oriented at 45 to the trajectory of the target. For example, a ground station located on the equator tracking a satellite with an equatorial orbit would have one axis parallel to northeast and southwest, and the other axis parallel to northwest and southeast. The diagonal-axes stage is considerably less vulnerable to backlash. If it is correctly oriented, its axes rotate in only one direction during an overhead pass by a satellite. As a result, the effects of backlash may be inherently eliminated. If the gravity-induced torque on either axis changes during the pass, then backlash may become important during the part of the pass where the gravity torque, instead of opposing the motion of the stage, pushes the stage in the direction of motion. This can result in the loss of gear-to-gear contact in one or more stages of the gear reduction mechanism. In this case, a preload spring used to eliminate backlash need only be sufficiently strong to overcome the gravity torque, i.e. it need not overcome friction in the gear train. The diagonal-axes stage is not backlash-free for arbitrary target trajectories such as an aircraft might execute. If properly oriented for any particular satellite, however, it is backlash-free for all passes of that satellite, which will trace out parallel paths on the sky, and for all passes of any other satellite that are perpendicular to the first. It will also be backlash-free for some fraction of other satellite trajectories.

Regehr, Martin W.↗
NASA NTRS2007

Core-Cutoff Tool

A tool makes a cut perpendicular to the cylindrical axis of a core hole at a predetermined depth to free the core at that depth. The tool does not damage the surrounding material from which the core was cut, and it operates within the core-hole kerf. Coring usually begins with use of a hole saw or a hollow cylindrical abrasive cutting tool to make an annular hole that leaves the core (sometimes called the plug ) in place. In this approach to coring as practiced heretofore, the core is removed forcibly in a manner chosen to shear the core, preferably at or near the greatest depth of the core hole. Unfortunately, such forcible removal often damages both the core and the surrounding material (see Figure 1). In an alternative prior approach, especially applicable to toxic or fragile material, a core is formed and freed by means of milling operations that generate much material waste. In contrast, the present tool eliminates the damage associated with the hole-saw approach and reduces the extent of milling operations (and, hence, reduces the waste) associated with the milling approach. The present tool (see Figure 2) includes an inner sleeve and an outer sleeve and resembles the hollow cylindrical tool used to cut the core hole. The sleeves are thin enough that this tool fits within the kerf of the core hole. The inner sleeve is attached to a shaft that, in turn, can be attached to a drill motor or handle for turning the tool. This tool also includes a cutting wire attached to the distal ends of both sleeves. The cutting wire is long enough that with sufficient relative rotation of the inner and outer sleeves, the wire can cut all the way to the center of the core. The tool is inserted in the kerf until its distal end is seated at the full depth. The inner sleeve is then turned. During turning, frictional drag on the outer core pulls the cutting wire into contact with the core. The cutting force of the wire against the core increases with the tension in the wire and, hence, with the frictional drag acting on the outer sleeve. As the wire cuts toward the center of the core, the inner sleeve rotates farther with respect to the outer sleeve. Once the wire has cut to the center of the core, the tool and the core can be removed from the hole. The proper choice of cutting wire depends on the properties of the core material. For a sufficiently soft core material, a nonmetallic monofilament can be used. For a rubber-like core material, a metal wire can be used. For a harder core material, it is necessary to use an abrasive wire, and the efficiency of the tool can be increased greatly by vacuuming away the particles generated during cutting. For a core material that can readily be melted or otherwise cut by use of heat, it could be preferable to use an electrically heated cutting wire. In such a case, electric current can be supplied to the cutting wire, from an electrically isolated source, via rotating contact rings mounted on the sleeves.

Gheen, Darrell↗
DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗
NASA NTRS1996

Advanced Intelligent System Application to Load Forecasting and Control for Hybrid Electric Bus

The primary motivation for this research emanates from providing a decision support system to the electric bus operators in the municipal and urban localities which will guide the operators to maintain an optimal compromise among the noise level, pollution level, fuel usage etc. This study is backed up by our previous studies on study of battery characteristics, permanent magnet DC motor studies and electric traction motor size studies completed in the first year. The operator of the Hybrid Electric Car must determine optimal power management schedule to meet a given load demand for different weather and road conditions. The decision support system for the bus operator comprises three sub-tasks viz. forecast of the electrical load for the route to be traversed divided into specified time periods (few minutes); deriving an optimal 'plan' or 'preschedule' based on the load forecast for the entire time-horizon (i.e., for all time periods) ahead of time; and finally employing corrective control action to monitor and modify the optimal plan in real-time. A fully connected artificial neural network (ANN) model is developed for forecasting the kW requirement for hybrid electric bus based on inputs like climatic conditions, passenger load, road inclination, etc. The ANN model is trained using back-propagation algorithm employing improved optimization techniques like projected Lagrangian technique. The pre-scheduler is based on a Goal-Programming (GP) optimization model with noise, pollution and fuel usage as the three objectives. GP has the capability of analyzing the trade-off among the conflicting objectives and arriving at the optimal activity levels, e.g., throttle settings. The corrective control action or the third sub-task is formulated as an optimal control model with inputs from the real-time data base as well as the GP model to minimize the error (or deviation) from the optimal plan. These three activities linked with the ANN forecaster proving the output to the GP model which in turn produces the pre-schedule of the optimal control model. Some preliminary results based on a hypothetical test case will be presented for the load forecasting module. The computer codes for the three modules will be made available fe adoption by bus operating agencies. Sample results will be provided using these models. The software will be a useful tool for supporting the control systems for the Electric Bus project of NASA.

Momoh, James↗
DOE OSTI2021

Net Zero Energy Model for Wastewater Treatment Plants

The primary objective of this study is to achieve net-zero energy (NZE) wastewater treatment plants (WWTPs) by utilizing energy efficiency opportunities (EEO), combined heat and power (CHP) systems, and other renewable energy (RE) sources, e.g., solar, water, and wind powers. Herein, this study discusses an innovative energy solution for WWTPs in the United States, and one of the WWTPs with a flow capacity of 1.5 million gallons per day (MGD) was selected as a case study. An optimization tool, Hybrid Optimization of Multiple Energy Resources (HOMER) software, is used in this study to find the best energy system configuration to run the system. An energy audit for one WWTP was conducted in early 2020 and the report is used to do this study. The proposed EEOs were able to reduce WWTP energy consumption by about 11%. The excess anaerobic digester gas was utilized in a CHP system to cover about 42% of the facility’s consumption. Also, 3% of the utility energy consumption can be claimed by microturbines in the aeration tanks. Another two renewable energy systems, solar photovoltaic (PV) with 29% and water turbines with 15%, contribute to covering 100% of the WWTP energy consumption and achieving an NZE WWTP.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2018

Influence of Load Profile on Biomechanics of the Squat and Deadlift

Long duration space travel will expose astronauts to extended periods of reduced gravity. Since gravity is not present to assist loading, astronauts will use resistive and aerobic exercise regimes for the duration of the space flight to counteract the effect reduced gravity has on the body. Astronauts will exercise on a flywheel based device on the second Orion Exploration Mission (EM2). The effect that the flywheel load profile has on biomechanics is unknown when compared to free weights or a simulated free weight profile. The purpose of this evaluation is to compare the differences in lower body kinematics and kinetics between the flywheel and free weight profile. Test subjects were instrumented with reflective markers for motion capture data collection while exercising on the Device for Aerobic and Resistive Training (DART) prototype developed by TDA Research, Inc. of Wheat Ridge, CO. Exercises performed were either the squat while wearing a harness or deadlift while grasping a T-bar, both of which interfaced with the DART through a rope cable. The DART, a motorized device controlled via software, is capable of producing different load profiles. Profiles include simulated free weights with adjustable eccentric overload capability and flywheel. Test variables included the applied device load and the load profile, both set through the DART software interface. Motion capture data was collected with a 12 camera system (Smart-DX, BTS Bioengineering, Brooklyn, NY). Bilateral ground reaction force data were collected with force plates (P6000, BTS Bioengineering). DART cable force was recorded through an internal load cell. Data was collected from a total of four test subjects. The three repetition maximum was determined for each test subject for both squat and deadlift. High, medium and low loads were determined based on this maximum. The test subject performed five repetitions of each exercise at each load and each test trial was repeated twice. Cadence was controlled during exercising. Biomechanical data were used to drive the models utilizing the OpenSim software platform. Subject specific models were scaled to match the anthropometrics of the test subjects and used to estimate the peak joint angle, joint range of motion, the peak joint moment and the joint moment impulse of the lower extremity joints and the lumbar joint.These are preliminary results because the data analysis is ongoing. There was a lot of inter-subject variability, however, in general, there was a greater peak lumbar flexion angle for the flywheel squat exercise. There was a trend towards a greater range of motion at the hip for the squat exercise with free weight. There was also a greater hip extension, lumbar extension and ankle plantar flexion impulse moment during the squat exercise with free weight. During the deadlift exercise, the peak knee flexion angle and peak knee extension moment were greater when using the free weight profile. For deadlift, the hip extension, lumbar extension and ankle plantar flexion impulse moment tended to be greater with the free weight profile. Overall, the kinematic and kinetic outcomes for the flywheel profile were either statistically the same as free weight profile in many cases, significantly reduced in a few cases, and rarely higher.

Bioengineering↗
NASA NTRS2006

Embedded Sensors for Measuring Surface Regression

The development and evaluation of new hybrid and solid rocket motors requires accurate characterization of the propellant surface regression as a function of key operational parameters. These characteristics establish the propellant flow rate and are prime design drivers affecting the propulsion system geometry, size, and overall performance. There is a similar need for the development of advanced ablative materials, and the use of conventional ablatives exposed to new operational environments. The Miniature Surface Regression Sensor (MSRS) was developed to serve these applications. It is designed to be cast or embedded in the material of interest and regresses along with it. During this process, the resistance of the sensor is related to its instantaneous length, allowing the real-time thickness of the host material to be established. The time derivative of this data reveals the instantaneous surface regression rate. The MSRS could also be adapted to perform similar measurements for a variety of other host materials when it is desired to monitor thicknesses and/or regression rate for purposes of safety, operational control, or research. For example, the sensor could be used to monitor the thicknesses of brake linings or racecar tires and indicate when they need to be replaced. At the time of this reporting, over 200 of these sensors have been installed into a variety of host materials. An MSRS can be made in either of two configurations, denoted ladder and continuous (see Figure 1). A ladder MSRS includes two highly electrically conductive legs, across which narrow strips of electrically resistive material are placed at small increments of length. These strips resemble the rungs of a ladder and are electrically equivalent to many tiny resistors connected in parallel. A substrate material provides structural support for the legs and rungs. The instantaneous sensor resistance is read by an external signal conditioner via wires attached to the conductive legs on the non-eroding end of the sensor. The sensor signal can be transmitted from inside a high-pressure chamber to the ambient environment, using commercially available feedthrough connectors. Miniaturized internal recorders or wireless data transmission could also potentially be employed to eliminate the need for producing penetrations in the chamber case. The rungs are designed so that as each successive rung is eroded away, the resistance changes by an amount that yields a readily measurable signal larger than the background noise. (In addition, signal-conditioning techniques are used in processing the resistance readings to mitigate the effect of noise.) Hence, each discrete change of resistance serves to indicate the arrival of the regressing host material front at the known depth of the affected resistor rung. The average rate of regression between two adjacent resistors can be calculated simply as the distance between the resistors divided by the time interval between their resistance jumps. Advanced data reduction techniques have also been developed to establish the instantaneous surface position and regression rate when the regressing front is between rungs.

Gramer, Daniel J.↗
NASA NTRS1997

The Solar-Stellar Connection (NAG5-6124: SOHO Guest Investigator Program)

The following is a final report from the SOHO Guest Investigator program to use the SUMER far-UV spectrometer to obtain imaging spectroscopy in support of the goals of the so-called "solar-stellar connection." In particular, a major emphasis was utilization of the long-slit time-resolved maps of the solar surface in bright far-UV emission lines to deduce how particular aspects of the temporally and spatially averaged line profiles trace back to individual structural features of the magnetically disturbed outer atmosphere; to help interpret the unresolved line profiles from high quality stellar observations (say, with the Space Telescope Imaging Spectrograph). The researchers served two tours of duty in the SOHO Operations Center as SUMER planners, during which time we conducted an extensive series of observing programs. These can be divided into three general categories: surface mapping, translimb spectroscopy, and active region diagnostics. We have analyzed some of the large volumes of data to the point where we have presented them in poster papers, and in invited papers at national and international meetings. Listed below are the titles of the preliminary publications we have written, including brief abstracts to indicate the main results. (1) Chromospheric structure and Dynamics-- Observations -- The chromosphere is a highly structured dynamic 'layer' of the solar outer atmosphere. Here, not only are the effects of mechanical heating first evident (moving upward in altitude from the deep photosphere), but also the amount of nonradiative energy deposited is far greater than in the albeit much hotter overlying transition region and corona. Further, the chromosphere is by far the thickest zone of the solar atmosphere with respect to the pressure scale height. A major goal of stellar astrophysics is to understand how the chromosphere is heated and why it adopts its peculiar structure. A cursory examination of solar filtergrams and high-resolution movies demonstrates that much of the chromospheric "action" must be occurring on fine spatial scales and short times; particularly in the cell interior transient brightenings, but also in the longer-lived network fragments. That regime of investigation is far removed from what one usually associates with "synoptic" measurements. Nevertheless, synoptic observations of chromospheric indices, filtergrams, and globally-averaged profile parameters not only can provide important insight concerning the crucial role of the cycle-variable part of the solar magnetic field; but they also can forge a key link with analogous measurements of the stars, where often the phenomena can be significantly exaggerated from the solar case, but high spatial resolution reconnaissance is not even a remote possibility. In addition to discussing the synoptic aspects of chromospheric structure and dynamics, I summarized new insights into the general problem of the solar chromosphere that have been obtained recently with the SUMER far-ultraviolet spectrometer on SOHO. (2) CO and the Temperature Structure of the Solar Atmosphere -- The surface layers of the Sun provide a crucial boundary condition for many of the processes that occur in the deep interior. The stratification of the outer solar atmosphere once was thought to be well understood. However, studies of thermally sensitive molecular absorptions in the infrared revealed puzzling anomalies. Strong lines of the CO fundamental vibration-rotation bands near 5 microns showed very cool temperatures at the extreme limb, and remarkable off-limb emissions extending well into the supposedly hot chromosphere. The conflicting pictures of the photosphere/chromosphere interface, from the widely separated wavelength regimes, has raised suspicions that those "layers" of the atmosphere are much more inhomogeneous than previously suspected. One proposal is that the low chromosphere is dominated by cool gas, the "COmosphere," which is threaded by a network of persistent small-scale hot magnetic filaments and occasionally disrupted by localized acoustic disturbances. The COmosphere is capped by the merged fields of the network elements in the chromospheric "canopy." (3) Translimb Spectroscopy with SOHO/SUMER -- We have used SUMER to obtain deep exposures of the 1300-1400 A spectrum, at the extreme limb and off-limb. Previous "translimb" studies in the thermal infrared had revealed remarkable extensions of cold material (T is approximately equal to 3000 K)-traced by carbon monoxide emission lines-into the heart of the hot chromosphere. A main objective of our program was to search for corresponding far-UV signatures of the "thermally-bifurcated" low chromosphere; for example, radiatively fluoresced emissions of the CO A-X 4th-positive system (collisional excitation would be negligible in cold gas). We conducted two separate observing programs with SUMER. Both made use of the 1 inch-diameter circular aperture, translated across the limb in the minimum motor step increments of 0."375, along the central meridian in the Northern polar coronal hole. The first program executed for nine hours beginning 19UT 25 Oct 1996. The full wavelength range was 1340-1400 A. It was recorded in two overlapping segments, placing key regions of the spectrum alternately on the KBr and bare parts of the detector, to help isolate 2nd-order features. Each segment was integrated for 500 s, and 32 pairs were obtained to span a 12" swath centered on the optical limb. The second program was conducted 00-09UT 01 Dec 1996. It consisted of a single wavelength setting (1300-1340 A) with exposure time 500 s, but twice the spatial coverage of the earlier series: 64 steps, for a total displacement of 24". The strong chromospheric resonance lines of atomic oxygen (1302-1305 A) and ionized carbon (1334-1335 A) were observed on the bare part of the MCP camera.

Ayres, Thomas R.↗