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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

On formulations for modeling pressurized cracks within phase-field methods for fracture

Over the past few decades, the phase-field method for fracture has seen widespread appeal due to the many benefits associated with its ability to regularize a sharp crack geometry. Along the way, several different models for including the effects of pressure loads on the crack faces have been developed. Further, this work investigates the performance of these models and compares them to a relatively new formulation for incorporating crack-face pressure loads. It is shown how the new formulation can be obtained either by modifying the trial space in the traditional variational principle or by postulating a new functional that is dependent on the rates of the primary variables. The key differences between the new formulation and existing models for pressurized cracks in a phase-field setting are highlighted. Model-based simulations developed with discretized versions of the new formulation and existing models are then used to illustrate the advantages and differences. In order to analyze the results, a domain form of the J-integral is developed for diffuse cracks subjected to pressure loads. Results are presented for a one-dimensional cohesive crack, steady crack growth, and crack nucleation from a pressurized enclosure.

42 ENGINEERING↗
DOE OSTI2024

Metal-Complex Inks for Lower Cost and Improved Passivation for Silicon Photovoltaic Metallization

This contribution introduces the silicon PV community to screen-printable metal-complex inks that potentially will reduce Ag usage in Si PV metallization to one-quarter and costs to one-third that of traditional particle-based pastes while also improving passivation. Metal-complex inks are formulated using a Tollen’s reaction to produce inks with a high percentage of diamminesilver (I) cations (22 wt %) in a solution of acetate and formate anions. When printed and dried, labile ammonia ligands evaporate, leaving behind silver cations which, when reduced by formate anions and acetic acid, plate out silver and silver acetate. When annealed to just 300 °C a dense metallic silver film forms with excellent conductivity, and adhesion to silicon. When compared to traditional particle-based screen-printing pastes, the metal-complex inks are much denser, have higher conductivity, use less Ag, and are a fraction of the cost. Importantly, the inks anneal from 90 – 450 °C allowing for improved passivation schemes compared with fired SiNx. This contribution highlights first experiments on the improved passivation of metallized poly-Si/SiO2 passivated contacts using metal-complex Ag inks.

Young, David L. (ORCID:0000000340970493)↗
DOE OSTI2023

Metal-Complex Inks for Lower Cost and Improved Passivation for Silicon Photovoltaic Metallization

This contribution introduces the silicon PV community to screen-printable metal-complex inks that potentially will reduce Ag usage in Si PV metallization to one-quarter and costs to one-third that of traditional particle-based pastes while also improving passivation. Metal-complex inks are formulated using a Tollen's reaction to produce inks with a high percentage of diamminesilver (I) cations (22 wt %) in a solution of acetate and formate anions. When printed and dried labile ammonia ligands evaporate, leaving behind silver cations which, when reduced by formate anions and acetic acid, plate out silver and silver acetate. When annealed to just 300 degrees C a dense metallic silver film forms with excellent conductivity, and adhesion to silicon. When compared to traditional particle-based screen-printing pastes, the metal-complex inks are much denser, have higher conductivity, use less Ag, and are a fraction of the cost. Importantly, the inks anneal from 90 - 450 degrees C allowing for better passivation schemes than fired SiNx. This contribution highlights first experiments on the improved passivation of metallized poly-Si/SiO2 passivated contacts using metal-complex, Ag inks compared with particle-based, fired pastes.

metal-complex ink↗
DOE OSTI2026

Electrolyte Design for Fast‐Charging Lithium‐Based Batteries

Fast charging is essential for the widespread adoption of lithium (Li)-ion batteries, but it is fundamentally limited by sluggish interfacial kinetics, Li plating, and electrolyte instability at high current densities. Over the past decade, electrolyte engineering has emerged as a key strategy to address these challenges. This review summarizes the development of fast-charging electrolytes over the past ten years and outlines a design framework. Electrolyte formulations are first deconstructed into their main components—solvents, salts, and functional additives—and representative strategies for tuning solvation structure and interphase chemistry are discussed to suppress Li plating and improve interfacial kinetics. The discussion then extends to advanced electrolyte systems, particularly localized high-concentration electrolytes (LHCEs), and their compatibility with different anode chemistries. Advanced characterization techniques are also summarized and categorized based on destructiveness, spatial and temporal resolution, quantitative analysis, and the chemical species or processes probed across multiple length scales. Recent progress in AI-enabled electrolyte discovery and battery management system (BMS) strategies for optimized fast-charging protocols is further highlighted. Finally, perspectives are presented on translating electrolyte innovations from academic research to practical applications, with emphasis on cell format, realistic operating conditions, and manufacturability.

25 ENERGY STORAGE↗
NASA NTRS1998

Phenylethynyl Containing Polyarylene Ethers/Polyimides Resin Infiltration of Composites

The following tasks were performed at NCA&TSU during the second year in performance of the grant. LaRC-LV-1 13 resin was synthesized at NCA&TSU. In order to perform the synthesis, glassware and needed apparatus were purchased with grant funds along with the appropriate monomers. It was found that the LaRC-LV-1 13 resin was easily synthesized by the NMP solvent/toluene imminization/distilled water precipitation process. However, in use this resin exhibited a bubbling/foaming behavior during cure that was detrimental leading to the production of composite panels having a high void content. Composite panels were fabricated using compression molding and resin transfer molding (RTM) techniques. Initial fiber volume determinations were computed at NCA&TSU along with NASA-Langley measured c-scans on the panels produced. The initial results indicated a unsatisfactory level of approximately 20% by volume of voids. Testing of uniaxial coupons in compression to failure also agreed with these results. The uniaxial coupons delaminated as the major mode of failure indicative of an unacceptably low level of resin and to much void content in the final composites produced. In discussions with Dr. Brian Jensen, it was suggested the void fraction needs to be reduced to at least 2% by volume for a useful composite. The panels produced used both resin synthesized at NASA-Langley and NCA&TSU. In reviewing our progress over the past year, it was noted that the resin as formulated by the current synthesis process bubbled at elevated temperature. This was especially observed in neat resin slugs cured at the recommended one, four and eight hour cure temperatures. Pressurized cures where then performed with pressures up to 200 psi and simultaneously the lowest eight hour cure temperatures. Although this procedure reduced the amount of bubbles to some extent in the neat resin slugs it did not completely eliminate them. The cure reaction appears to be very energetic even at the lowest recommended cure temperature. Currently, the pressurized cure apparatus developed at NCA&TSU is limited to 200 psi.

Dunn, DeRome O.↗
DOE OSTI2020

Repurposing a microfluidic formulation device for automated DNA construction

Microfluidic applications have expanded greatly over the past decade. For the most part, however, each microfluidics platform is developed with a specific task in mind, rather than as a general-purpose device with a wide-range of functionality. Here, we show how a microfluidic system, originally developed to investigate protein phase behavior, can be modified and repurposed for another application, namely DNA construction. We added new programable controllers to direct the flow of reagents across the chip. We designed the assembly of a combinatorial Golden Gate DNA library using TeselaGen DESIGN software and used the repurposed microfluidics platform to assemble the designed library from off-chip prepared DNA assembly pieces. Further experiments verified the sequences and function of the on-chip assembled DNA constructs.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1979

Calculations of transonic boattail flow at small angle of attack

A transonic flow past a boattailed afterbody under a small angle of attack was examined. It is known that the viscous effect offers significant modifications of the pressure distribution on the afterbody. Thus, the formulation for the inviscid flow was based on the consideration of a flow past a nonaxisymmetric body. The full three dimensional potential equation was solved through numerical relaxation, and quasi-axisymmetric boundary layer calculations were performed to estimate the displacement effect. It was observed again that the viscous effects were not negligible. The trend of the final results agreed well with the experimental data.

Nakayama, A.↗
NASA NTRS1977

Three dimensional steady and unsteady asymmetric flow past wings of arbitrary planforms

The nonlinear discrete vortex method was extended to treat the problem of asymmetric flows past a wing with leading-edge separation, including steady and unsteady flows. The problem was formulated in terms of a body-fixed frame of reference, and the nonlinear discrete vortex method was modified accordingly. Only examples of flows past delta wings are presented. Comparison of these results with experimental results for a delta wing undergoing a steady rolling motion at zero angle of attack demonstrates the superiority of the present method in obtaining highly accurate loads. Numerical results for yawed wings at large angles of attack are also presented. In all cases, total load coefficients, pressure distributions and shapes of the free-vortex sheets are shown.

Kandil, O. A.↗
NASA NTRSDate not supplied

Lessons Learned on the Use of Data Surfaces for Ffowcs Williams-Hawkings Calculations: Airframe Noise Applications

The use of integral solutions to the acoustic analogy-based Ffowcs Williams-Hawkings (FW-H) formulation is the defacto industrial and academic approach for assessing far-field acoustic behavior from airframe noise simulations. The methodology utilizes time-accurate flow variables obtained at arbitrary data surfaces to determine far-field spectra. The solid surface approach, where the time history of pressure is recorded on the surface of the aircraft, is generally preferred. Permeable surfaces, where pressure and velocity are recorded on a user-defined surface enclosing the aircraft, are also used. This paper seeks to share some of the valuable lessons we learned over the past several years on the limitations of the FW-H formulation and best practices for its successful application. We show results for various configurations comprising isolated landing gears, a business jet, a large commercial transport, and a generic low boom supersonic prototype, all at landing conditions. We demonstrate that the solid FW-H approach has significant accuracy limitations for most realistic cases and that the permeable FW-H approach may also fail in specific scenarios, requiring additional costly steps to extract the correct far-field noise spectra. Suggested guidelines for proper FW-H calculations are also given.

Acoustic propagation, Ffowcs Williams-Hawkings Cal↗
NASA NTRS1978

Three dimensional steady and unsteady asymmetric flow past wings of arbitrary planforms

The nonlinear discrete vortex method is extended to treat the problem of asymmetric flows past a wing with leading edge separation, including steady and unsteady flows. The problem is formulated in terms of a body fixed frame of reference and the nonlinear-discrete vortex method is modified accordingly. Although the method is general, only examples of flows past delta wings are presented due to the availability of experimental data as well as approximate theories. Comparison of results with experimental results for a delta wing undergoing a steady rolling motion at zero angle of attack demonstrate the superiority of the present method over existing approximate theories in obtaining highly accurate loads. Numerical results for yawed wings at large angles of attack are also presented. In all cases, total load coefficients, pressure distributions, and shapes of the free vortex sheets are shown.

Kandil, O. A.↗
DOE OSTI2021

Topology optimization of additively manufactured fluidic components free of internal support structures

This report integrates projection-based approaches for implementing overhang constraints with fluid topology optimization to design additively manufactured fluidic components that do not require internal support structures. Internal support structures are challenging, potentially impossible to remove in complex fluid networks, yet would degrade fluidic performance if left within the part. This presents a major challenge in coupling topology optimization with additive manufacturing in the design of fluid components. The proposed approach leverages past work in overhang constraints for solid mechanics, including projection formulations and adjoint sensitivity analysis, and considers incompressible Navier–Stokes equations for laminar fluid flow. The approach is demonstrated on 2D and 3D fluid topology optimization problems to minimize pressure drop and constrain mass flow rates in pipes and manifolds. Resulting designs are crisp, logical, satisfy performance constraints, and satisfy overhang constraints, eliminating the need for internal support structures.

42 ENGINEERING↗
DOE OSTI2021

Optimization of Carbon-Nanotube-Reinforced Composite Gridlines Towards Commercialization

Solar cells in PV modules crack during field operation from environmental stressors, including extreme weather events, such as hailstorms and hurricanes. These cracks can lead to gradual or immediate acute power degradation. To directly address cell-crack-induced degradation, we have formulated a carbon nanotube additive for commercial screen printed silver pastes. We have shown in previous work that these metal matrix composites have little to no effect on the cell’s efficiency while enhancing the metallization’s fracture toughness and electrical gap-bridging capability. In this work, we focus on optimizing the composite metallization to achieve the best possible performance. We discover that reducing carbon nanotube agglomerations in the paste not only improves the printability for narrow gridlines, but also increases the modulus of toughness of the metallization by over 500%.

carbon nanotubes↗
DOE OSTI2022

Translating Material-Level Characterization of Carbon-Nanotube-Reinforced Composite Gridlines to Module-Level Degradation

Cell cracks in PV modules caused by poor handling during shipping and installation as well as from extreme weather events can lead to gradual or immediate power degradation. To directly address cell-crack-induced degradation, we have formulated a carbon nanotube additive for commercial screen printed silver pastes. We have shown in previous work that these metal matrix composites have little to no effect on the cell's efficiency while enhancing the metallization's fracture toughness and electrical gap-bridging capability. In this work, we focus on translating materials level characterization techniques to module level degradation. We found that we get conflicting results from two different methods of measuring the metallization's ability to electrically bridge gaps in cracked solar cells. Mini-module stress testing is currently underway to determine which materials characterization correlates well with the min-module degradation characteristics.

carbon nanotubes↗
NASA NTRS1987

Stability of viscous flow past a circular cylinder

A spectral method which employs trigonometric functions and Chebyshev polynomials is used to compute the steady, incompressible laminar flow past a circular cylinder. Linear stability methods are used to formulate a pair of decoupled generalized eigenvalue problems for the growth of symmetric and asymmetric (about the dividing streamline) perturbations. It is shown that, while the symmetric disturbances are stable, the asymmetric perturbations become unstable at a Reynolds number about 40 with a Strouhal number about 0.12. The critical conditions are found to depend on the size of the computational domain in a manner similar to that observed in the laboratory.

Zebib, A.↗
NASA NTRS1993

Multiple degree of freedom force-state component identification

Force-state mapping is extended to allow the quasistatic characterization of realistic multiple degree of freedom systems whose constitutive relations are nonlinear, dissipative, coupled and depend on memory of past states. A general constitutive force-state model is formulated, which includes dynamic hysteresis phenomena typical of that found in deployable structures. A two step parameter identification approach is developed, which employs a linear extended Kalman filter and a nonlinear least squares fit. A six degree of freedom force-state testing device was constructed, and used to obtain data on one bay of a simple truss and on one bay of the MODE deployable truss.

Masters, Brett P.↗
NASA NTRS2011

End-of-Life Optical Property Predictions of White Conductive Thermal Control Coatings through Analysis of On-Orbit and Ground Based Testing Data

New system requirements pertaining to thermal optical properties and coating electrical properties are commonly specified on non-low earth orbit missions. An increasing number of projects are specifying coatings with a surface resistivity of less than lE-9 ohm/square to mitigate electrostatic charge buildup events over a range of operational temperatures. There are a limited number of coatings that. meet these electrical property requirements while having flight derived optical properties in representative environments. Goddard Space Flight Center Code 546, Contamination and Thermal Coatings Group has recently explored the variety of electrically conductive white coatings available through domestic vendors to evaluate properties to meet project requirements in a geostationary orbit. The lack of significant flight data in representative environments required the careful selection of samples in ground based tests to establish end of life thermal properties. Attention must be given to the origin and pedigree of samples used on past on-orbit experiments to insure that the present formulations for the materials are similar and will react in similar manner.

Hasegawa, Mark↗
NASA NTRS1992

A finite element study of incompressible flows past oscillating cylinders and aerofoils

We present our numerical results for certain unsteady flows past oscillating cylinders and aerofoils. The computations are based on the stabilized space-time finite element formulation. The implicit equation systems resulting from the space-time finite element discretizations are solved using iterative solution techniques. One of the problems studied is flow past a cylinder which is forced to oscillate in the horizontal direction. In this case we observe a change from an unsymmetric mode of vortex shedding to a symmetric one. An extensive study was carried out for the case in which a cylinder is mounted on lightly damped springs and allowed to oscillate in the vertical direction. In this case the motion of the cylinder needs to be determined as part of the solution, and under certain conditions this motion changes the vortex-shedding pattern of the flow field significantly. This nonlinear fluid-structure interaction exhibits certain interesting behavior such as 'lock-in' and 'hysteresis', which are in good agreement with the laboratory experiments carried out by other researchers in the past. Preliminary results for flow past a pitching aerofoil are also presented.

Mittal, S.↗
NASA NTRS1988

Formulation and verification of frequency response system identification techniques for large space structures

For the past several years much effort has been given to the development of techniques for designing control systems for large space structures (LSS's). The main objective of these efforts has been to develop a LSS control methodology that produces designs that meet strenuous performance requirements and are robust to model inaccuracies. Unfortunately, performance and robustness are conflicting requirements. Because LSS's can not be fully tested on ground, it has become an accepted fact that the design of LSS control systems to meet performance requirements can not be completed until the LSS is placed on-orbit and tested and an accurate model is extracted from on-orbit test results. Modern MIMO sampled-data frequency response design techniques are viable candidates for designing LSS control systems. First, this paper presents techniques for performing MIMO system identification (ID) from test data. Then, techniques for improving the performance of the system ID process in the presence of noise are presented. Finally, practical utility of the system ID approaches are validated by the presentation of results obtained from application on the LSS Ground Test Facility at Marshall Space Flight Center.

Mitchell, Jerrel R.↗