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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
NASA NTRS2001

Multidisciplinary Aerospace Systems Optimization: Computational AeroSciences (CAS) Project

The report describes a method for performing optimization of a system whose analysis is so expensive that it is impractical to let the optimization code invoke it directly because excessive computational cost and elapsed time might result. In such situation it is imperative to have user control the number of times the analysis is invoked. The reported method achieves that by two techniques in the Design of Experiment category: a uniform dispersal of the trial design points over a n-dimensional hypersphere and a response surface fitting, and the technique of krigging. Analyses of all the trial designs whose number may be set by the user are performed before activation of the optimization code and the results are stored as a data base. That code is then executed and referred to the above data base. Two applications, one of the airborne laser system, and one of an aircraft optimization illustrate the method application.

Kodiyalam, S.↗
DOE OSTI2023

Extend an innovative HPC-Compatible Multiple Temporal-spatial Resolution Concurrent Finite Element Modeling Approach to Guide Laser Powder Bed Fusion Additive

Laser power bed fusing (PBF) additive manufacturing is a key enabling technology to manufacture highly complex and integrated automotive structures. However, the geometric complexity of PBF-AM technique also leads to highly non-uniform heating and cooling rate in the manufactured part, which may cause flaw formation and produce excessive and nonuniform residual stresses, which increase quality uncertainties and manufacture issues, leading to increases in cost and energy consumption in the form of rejected parts. In this research project, we developed an innovative Multi-Spatial-Temporal-Resolution Finite Element (MUST-FE) method and completed the corresponding high performance computation (HPC) platform-based in-house code, which enables high accuracy prediction of temperature and residual stress fields for component-scale PBF-AM manufacture in efficient computation time. The MUST-FE model is calibrated and validated with a “2D pad” AlSi10Mg experiments by matching the melt pool shape and dimension, and with a “XY-cross” AlSi10Mg experiment by matching the thermal distortion and residual stress. The innovative multi-resolution and concurrent modeling approach adopted in this code ensures accuracy and computational efficiency, which will enable energy-efficient and high-yield, low-cost manufacturing of optimized, qualifiable automotive structures and contribute towards reaching technical targets outlined in AMO’s Program Plan to develop additive manufacturing systems that deliver consistently reliable parts with predictable properties.

36 MATERIALS SCIENCE↗
NASA NTRS1982

The local dispersion relation for magneto-atmospheric waves

The local dispersion relation for magneto-atmospheric waves is discussed in terms of the linearized theory of waves in a plane-stratified, inviscid, perfectly conducting atmosphere under uniform gravity. The normally used local dispersion relation is demonstrated to not be unique, depending instead on the order of derivation from the fundamental first-order perturbation equations of continuity, momentum, energy, and induction. Furthermore, it is shown that the local dispersion relation predicts that the cutoff frequency decreases with increasing magnetic field strength, while the WKB approximation method projects an increase in the cutoff frequency with increasing magnetic field strength. A new form of the local dispersion relation is developed, and consideration is given to the special case of a global dispersion relation in conditions of an isothermal atmosphere with a horizontal magnetic field.

Thomas, J. H.↗
NASA NTRS1992

Validating a large geophysical data set: Experiences with satellite-derived cloud parameters

We are validating the global cloud parameters derived from the satellite-borne HIRS2 and MSU atmospheric sounding instrument measurements, and are using the analysis of these data as one prototype for studying large geophysical data sets in general. The HIRS2/MSU data set contains a total of 40 physical parameters, filling 25 MB/day; raw HIRS2/MSU data are available for a period exceeding 10 years. Validation involves developing a quantitative sense for the physical meaning of the derived parameters over the range of environmental conditions sampled. This is accomplished by comparing the spatial and temporal distributions of the derived quantities with similar measurements made using other techniques, and with model results. The data handling needed for this work is possible only with the help of a suite of interactive graphical and numerical analysis tools. Level 3 (gridded) data is the common form in which large data sets of this type are distributed for scientific analysis. We find that Level 3 data is inadequate for the data comparisons required for validation. Level 2 data (individual measurements in geophysical units) is needed. A sampling problem arises when individual measurements, which are not uniformly distributed in space or time, are used for the comparisons. Standard 'interpolation' methods involve fitting the measurements for each data set to surfaces, which are then compared. We are experimenting with formal criteria for selecting geographical regions, based upon the spatial frequency and variability of measurements, that allow us to quantify the uncertainty due to sampling. As part of this project, we are also dealing with ways to keep track of constraints placed on the output by assumptions made in the computer code. The need to work with Level 2 data introduces a number of other data handling issues, such as accessing data files across machine types, meeting large data storage requirements, accessing other validated data sets, processing speed and throughput for interactive graphical work, and problems relating to graphical interfaces.

Kahn, Ralph↗
DOE OSTI2022

Montage electron tomography of vitrified specimens

Cryo-electron tomography provides detailed views of macromolecules in situ. However, imaging a large field of view to provide more cellular context requires reducing magnification during data collection, which in turn restricts the resolution. To circumvent this trade-off between field of view and resolution, we have developed a montage data collection scheme that uniformly distributes the dose throughout the specimen. In this approach, sets of slightly overlapping circular tiles are collected at high magnification and stitched to form a composite projection image at each tilt angle. These montage tilt-series are then reconstructed into massive tomograms with a small pixel size but a large field of view. For proof-of-principle, we applied this method to the thin edge of HeLa cells. Thon rings to better than 10 Å were detected in the montaged tilt-series, and diverse cellular features were observed in the resulting tomograms. These results indicate that the additional dose required by this technique is not prohibitive to performing structural analysis to intermediate resolution across a large field of view. We anticipate that montage tomography will prove particularly useful for lamellae, increase the likelihood of imaging rare cellular events, and facilitate visual proteomics.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1986

Speckle interferometry of asteroids. III - 511 Davida and its photometry

Photometric interferometry data on the fifth largest minor planet, 511 Davida, are used to generate orbital elements and physical dimensions. The Seward 2.3 m telescope was employed to obtain the speckle interferometric data. The asteroid was assumed to be a uniform-surfaced triaxial ellipsoid rotating about its shortest axis. A simultaneous amplitude-magnitude aspect method is defined for determining the pole position of the object, which is calculated to be within 4 deg of (307 deg; +32). A weighted amplitude aspect relation provides similar data. The albedos are estimated to lie within the range 0.24-0.42, and an a/b axial ratio of 0.97-1.66 is projected. The variations in the photometric albedos are taken as evidence of a nonuniform surface, a conclusion similar to that reached after earlier photometric measurements of the asteroid Herculina.

Drummond, J. D.↗
DOE OSTI2026

Numerical Investigation of Fluid Flow and Space Charge in Liquid Argon Time Projection Chamber (LArTPC) Detectors

Overview This project focused on developing a high-fidelity numerical framework to simulate the multiphysics environment within Liquid Argon Time Projection Chamber (LArTPC) detectors. The primary objective was to characterize the complex interplay between ion transport, background fluid dynamics, and electric field distortions—a critical factor for the calibration and sensitivity of next-generation High Energy Physics experiments, such as DUNE. Technical Achievements The research successfully yielded a hybrid numerical space-charge solver utilizing a Cell-Centered Finite Volume Method (FVM) for ion transport coupled with a Finite Element Method (FEM) for electric potential. Key accomplishments include: • Verification & Validation: The 3-D solver was rigorously verified against 1-D analytical solutions, demonstrating high numerical accuracy in predicting space-charge-induced field deviations. • Field Distortion Analysis: 3D simulations revealed that space charge effects introduce significant non-uniformities in the electric field. Critically, the research identified that background LAr flow velocities, when comparable to ion drift velocities, markedly exacerbate these distortions. • Technology Transfer: The resulting source code and comprehensive user manuals were successfully transferred to collaborators at Fermilab, providing a portable computational tool for the broader scientific community. Challenges and Future Directions While the space-charge solver achieved all performance metrics, the integrated fluid dynamics modeling encountered convergence challenges stemming from the extreme 200-fold disparity in length scales between the detector's 37 mm inlet pipes and the 8-meter global domain. To address this, the project has identified a clear technical pivot toward Hierarchical Geometric Adaptive Mesh Refinement (HG-AMR). By implementing an h-type refinement strategy with hanging nodes, future iterations of this solver will be capable of resolving localized high-gradient inlet flows without the prohibitive computational costs of regular grids. This advancement, combined with data-driven uncertainty quantification based on MicroBooNE-style calibration, will enable the precise modeling of detector responses in large-scale cryogenic environments where direct measurement remains difficult. Impact The computational tools developed under this award provide a foundation for enhancing the energy resolution and spatial reconstruction of noble liquid detectors. By bridging the gap between theoretical fluid dynamics and experimental field calibration, this work supports the DOE’s mission to advance the frontiers of neutrino physics and dark matter detection.

42 ENGINEERING↗
DOE OSTI2021

Optimal Header Design for Diffusion Bonded Heat Exchangers

Microchannel heat exchangers have seen increasing adoption in many high-pressure applications in recent decades but are subject to particulate fouling from the relatively small channel size compared to traditional designs. Typical cleaning methods require process shutdown, heat exchanger removal, cleaning, then reassembly. The objective of this project was to refine and transfer technology to enable header design improvements for Cleaning-in-Place (CIP), allowing for reduced/negligible process interruption for the cleaning process. The technology transfer was from Sandia National Laboratories (Sandia) to Vacuum Process Engineering, Inc. (VPE). This primary purpose of CIP was developed while considering channel flow uniformity and heat exchanger cost. The project phases were to 1) capture and define potential improvement options, 2) evaluate options with both simulation and experiments, and 3) transfer design knowledge to the industry partner. These efforts resulted in improved header designs from the first known focused effort in this area. The improved designs will help the entire microchannel heat exchanger field that has applications in supercritical CO 2 power cycles, hydrogen (fuel cell) vehicle fueling, liquified natural gas processing, and more.

42 ENGINEERING↗
DOE OSTI2024

CRADA Number NFE-21-08827 with DayLyte, Inc. (CRADA Final Report)

DayLyte Batteries is developing an aqueous Sodium-Air battery made with abundant materials while being half to a third the weight of Li-ion to power electric aircraft, electric vehicles and provide renewable energy on demand. To make this battery practical, DayLyte is developing a thin film ceramic Nasicon solid electrolyte amenable to rapid scaleup as well as a protective coating that will protect the solid electrolyte from 50wt% NaOH during the battery’s end-of-discharge while still allowing Na-ions to pass back and forth. If the thin film solid electrolyte and stable coating can be developed it will open the world to step change in battery performance all while not sacrificing the environment on the way. The project was designed to first focus on making and characterizing the Nasicon membrane followed by measuring its electrochemical performance, then assembling a full cell, optimizing its NaOH stability and then optimize the overall prototype design. Over the past two years, we have significantly improved the Nasicon film uniformity, demonstrated protective ligands that are stable in 50wt% NaOH by measuring no mass change with a quartz crystal microbalance, tested different heating methods like tube furnace and rapid heating and developed glassy carbon coatings on the current collector to prevent Nasicon-current collector alloying. We have found that getting film uniformity as measured by electrochemical impedance spectroscopy (EIS) is difficult because of different factors like surface roughness, deposition uniformity and heat treatment time and uniformity. The glassy carbon coating should significantly reduce the surface roughness and by tuning the coating conditions the film deposition uniformity improves and using an automated heating method should lead to much improved film uniformity.

25 ENERGY STORAGE↗
DOE OSTI2024

Designing Track for Electrospinning Unit and Cost-Effective Laser Scanning System

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
DOE OSTI2024

Designing a track for an electrospinning unit and cost-effective laser scanning system

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
DOE OSTI2025

Assessment of Self-interrogation Safeguards Signatures for Pebble Bed Reactor Fuel

New reactor designs, such as pebble-bed reactors, present challenges for the safeguarding of fissile material. Due to the multi-pass fuel circulation design and the non-uniform path a pebble may traverse through a pebble-bed reactor, there will be variations in the irradiation history of spent fuel pebbles. The standard approach of estimating actinide quantities based on fission gamma spectra or neutron emission paired with depletion modeling may yield uncertainties too large for safeguards and material accountancy. This project investigated, through modeling and experimentation, the potential of neutron self-interrogation of spent fuel pebbles as an innovative method to implement materials accountability. As an example, our feasibility studies indicate that the mass of U-235, U-238, Pu-239 and Pu-241 can be predicted to 4.1, 0.86, 13 and 13 % accuracy, respectively, when measuring 100 closely packed end-of-life spent fuel pebbles over approximately 12 days using a 4π counting geometry.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1992

Aeroelastic stability analyses of two counter rotating propfan designs for a cruise missile model

Aeroelastic stability analyses were performed to insure structural integrity of two counterrotating propfan blade designs for a NAVY/Air Force/NASA cruise missile model wind tunnel test. This analysis predicted if the propfan designs would be flutter free at the operating conditions of the wind tunnel test. Calculated stability results are presented for the two blade designs with rotational speed and Mach number as the parameters. A aeroelastic analysis code ASTROP2 (Aeroelastic Stability and Response of Propulsion Systems - 2 Dimensional Analysis), developed at LeRC, was used in this project. The aeroelastic analysis is a modal method and uses the combination of a finite element structural model and two dimensional steady and unsteady cascade aerodynamic models. This code was developed to analyze single rotation propfans but was modified and applied to counterrotating propfans for the present work. Modifications were made to transform the geometry and rotation of the aft rotor to the same reference frame as the forward rotor, to input a non-uniform inflow into the rotor being analyzed, and to automatically converge to the least stable aeroelastic mode.

Mahajan, Aparajit J.↗
NASA NTRS1992

Minimization of the vibration energy of thin-plate structure

An optimization method is proposed to reduce the vibration of thin plate structures. The method is based on a finite element shell analysis, a modal analysis, and a structural optimization method. In the finite element analysis, a triangular shell element with 18 dof is used. In the optimization, the overall vibration energy of the structure is adopted as the objective function, and it is minimized at the given exciting frequency by varying the thickness of the elements. The technique of modal analysis is used to derive the sensitivity of the vibration energy with respect to the design variables. The sensitivity is represented by the sensitivities of both eigenvalues and eigenvectors. The optimum value is computed by the gradient projection method and a unidimensional search procedure under the constraint condition of constant weight. A computer code, based on the proposed method, is developed and is applied to design problems using a beam and a plate as test cases. It is confirmed that the vibration energy is reduced at the given exciting frequency. For the beam excited by a frequency slightly less than the fundamental natural frequency, the optimized shape is close to the beam of uniform strength.

Inoue, Katsumi↗
NASA NTRS2017

Improving Estimation of Ground Casualty Risk From Reentering Space Objects

A recent improvement to the long-term estimation of ground casualties from reentering space debris is the further refinement and update to the human population distribution. Previous human population distributions were based on global totals with simple scaling factors for future years, or a coarse grid of population counts in a subset of the world's countries, each cell having its own projected growth rate. The newest population model includes a 5-fold refinement in both latitude and longitude resolution. All areas along a single latitude are combined to form a global population distribution as a function of latitude, creating a more accurate population estimation based on non-uniform growth at the country and area levels. Previous risk probability calculations used simplifying assumptions that did not account for the ellipsoidal nature of the Earth. The new method uses first, a simple analytical method to estimate the amount of time spent above each latitude band for a debris object with a given orbit inclination and second, a more complex numerical method that incorporates the effects of a non-spherical Earth. These new results are compared with the prior models to assess the magnitude of the effects on reentry casualty risk.

Ostrom, Chris L.↗
NASA NTRS2017

Improving Estimation of Ground Casualty Risk from Reentering Space Objects

A recent improvement to the long-term estimation of ground casualties from reentering space debris is the further refinement and update to the human population distribution. Previous human population distributions were based on global totals with simple scaling factors for future years, or a coarse grid of population counts in a subset of the world's countries, each cell having its own projected growth rate. The newest population model includes a 5-fold refinement in both latitude and longitude resolution. All areas along a single latitude are combined to form a global population distribution as a function of latitude, creating a more accurate population estimation based on non-uniform growth at the country and area levels. Previous risk probability calculations used simplifying assumptions that did not account for the ellipsoidal nature of the earth. The new method uses first, a simple analytical method to estimate the amount of time spent above each latitude band for a debris object with a given orbit inclination, and second, a more complex numerical method that incorporates the effects of a non-spherical Earth. These new results are compared with the prior models to assess the magnitude of the effects on reentry casualty risk.

Ostrom, C.↗
DOE OSTI2021

Cold Sintered Ceramics and Cements for Part Encapsulation

In this project, ceramic encapsulation materials were studied for high temperature (>~°500 C) applications where typical polymer encapsulants are unstable. A new low temperature (<~°200 C) method of processing ceramics, the cold sintering process was examined. Additionally, commercially available high temperature ceramic cements were investigated. In both cases, the mechanical strengths of available materials are less than desired (i.e., desired strengths similar to Si 3 N 4 ), limiting applicability. Composite designs to increase mechanical strength are suggested. Additionally, non-uniformities in stresses and densification while embedding alumina sheets in encapsulants via cold sintering using uni-axial pressing led to fracture of sheets, and an alternative iso-static based approach is recommended for future studies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Advanced electrode manufacturing to enable low cost PEM electrolysis

A critical challenge for the implementation of proton exchange membrane (PEM)-based water electrolyzers for the H2@Scale vision is the capital cost, which is largely driven by related factors of overdesign and highly manual legacy manufacturing methods. Typical electrolyzer cells have an order of magnitude higher membrane thickness and catalyst loading vs. fuel cells, in part because the manufacturing methods being used are not capable of producing uniform and reliable electrodes on thin membranes with low loading. Advanced electrode manufacturing is therefore the key enabler to reduce the cost of the electrolyzer stack, particularly roll-to-roll (R2R) manufacturing of catalyst coated layers (CCLs) and catalyst coated membranes (CCMs). The electrolyzer manufacturing process still relies on traditional sheet-to-sheet (S2S) processes, which requires intensive labor to make parts to meet the specification requirements. This project leverages fuel cell expertise (GM) with Proton’s knowledge of electrolyzer components to develop the electrocatalyst ink formulations and coating processes using slot die (ORNL) and gravure (NREL) coatings, with proof of concept at the pilot-scale (Kodak).

08 HYDROGEN↗