Next-Generation Wall Retrofit Panels with Integrated VIPS: Post-Retrofit Final Report
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Iffa, Emishaw [ORNL]↗
SEARCH · Engineering Papers
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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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Verification and Validation of Flow Confinement Modeling using OpenFAST Source Panel Method
Blockage or flow confinement effects in scale wind and water turbine testing in experimental facilities, including wind and water tunnels and tow tanks, can significantly alter incident aerodynamic and hydrodynamic loads, turbine performance (thrust, torque, power output), and wake dynamics compared to unconfined conditions. As scale model tests are key sources of OpenFAST model validation measurements, directly modeling flow confinement and its effects in OpenFAST enables improved model validat
Kim, Dongyoung [Sandia National Laboratories (SNL-↗
Component pose reconstruction using a single robotic total station for panelized building envelopes
The construction industry can benefit greatly from increased automation in construction processes in terms of precision, time, and labor costs. This is especially true for prefabricated construction for either new buildings or envelope retrofits. Here, prefabricated components are manufactured offsite according to design specifications and installed onsite. Accurate information on the components position and orientation (pose) is needed to achieve this. A tool named Real-Time Evaluator (RTE), designed to autonomously track prefabricated components as they are being installed and provide real-time installation instructions, is currently under development using a single robotic total station. This is challenging since at least three points are needed to determine the pose of an object in space. To achieve this goal with a single robotic total station, two key algorithms were developed: the resection algorithm aligns the digital twin with the physical twin regardless of the location of the total station, and the transformation algorithm gives instructions of translations and rotations to installers to achieve the desired installation pose. The algorithms were evaluated experimentally on a lab-scale demonstration. Results show that the resection algorithm achieved an average error of < 3.1 mm, while the transformation algorithm predicted the rotation angle along a single axis with an error of < 0.5◦.
Tang, Mengjia↗
Quality Investigation of Pultruded Carbon Fiber Panels Subjected to Four-Point Flexure via Fiber Optic Sensing
Pultruded carbon fiber-reinforced composites are attractive to the wind energy industry due to the rapid production of highly aligned unidirectional composites with enhanced fiber volume fractions and increased specific strength and stiffness. However, high volume carbon fiber manufacturing remains cost-prohibitive. This study investigates the feasibility of a pultruded low-cost textile carbon fiber-reinforced epoxy composite as a promising material in spar cap production was undertaken based on mechanical response to four-point flexure loading. As spar caps are primarily subjected to flexural loading, large-span four-point flexure was considered, and coupon testing was restricted to tensile modulus and compression strength assessment. High-resolution spatial fiber optic strain sensing was utilized to determine spatial strain distribution during four-point flexure, revealing consistent strain along the length of the part and proved to be an excellent option for process manufacturing quality examination. Additionally, holes with diameters of 2.49 mm, 5.08 mm, and 1.93 mm were drilled through the thickness of full-width parts to determine the feasibility of structural health monitoring of pultruding parts internal to wind blades via fiber optic strain sensing.
Chemistry↗
Upgrading ATR’s Diesel Generator Control Panels
This poster examines different upgrades made to ATR's diesel generator and how they can help improve reliability, performance, and safety.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Performance Evaluation of Vacuum Insulated Panel (VIP) Retrofits
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Iffa, Emishaw [ORNL]↗
2024 ANS Conference T-REXC Overview for MARVEL Panel
Overview of TREAT Micro-Reactor Experiment Cell (T-REXC)
21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
Performance Assessment Supporting the WIPP Replacement Panels Planned Change Request
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King, Seth John [Sandia National Laboratories (SNL↗
Investigation of Flux Spreading in a Light-Trapping, Planar-Cavity Receiver for Enclosed Solar Particle Heating
Concentrating solar thermal power (CSP) technology development has recently focused on increasing the operating temperatures to accommodate high efficiency power cycles and thermochemical processes. Inert solid particles as heat transfer media enable solar receivers to operate above 700 degrees Celsius resulting in increased system thermal efficiency compared to the conventional molten salt based CSP system. An open-cavity falling-particle solar receiver that can efficiently heat particles by direct heating from concentrated solar radiation faces challenges with large particle losses from wind and unable to support thermochemical reactions. A light-trapping, planar cavity reiver (LTPCR) where particles are indirectly heated can significantly minimize the particle losses during the operation, support thermochemical reactions, and offer scalability potential. The LTPCR features an array of vertical planar receiver/absorber panels arranged within a cavity configuration. Concentrated solar radiation from heliostats is focused onto the receiver walls, where heat is indirectly transferred to solid particles flowing inside the receiver channels. Heat transfer occurs through direct contact between the receiver panel walls and particles, and can be enhanced by fluidizing particles with air. This fluidization increases particle-wall contact and extends particle residence time, maximizing heat transfer efficiency. The unique vertical planar receiver structure originated from a near-blackbody tubular light absorber, effectively distributing the incoming solar beam spread across the panel walls and trapping light. This flux spreading effect, driven by cosine projection, converts high incident solar flux into a lower, more uniform heat flux on the panel walls. This redistribution enhances heat transfer efficiency between particle-wall or reaction gases-wall, while preventing localized overheating of the receiver panel. Indirect planar cavity solar receivers completely separate solid particles from the ambient environment that can greatly reduce the thermal losses in heated particles resulting in high efficiency at high temperatures above 700 degrees Celsius. This design ensures no particle losses to the environment during the operation while open-cavity designs can experience significant particle losses from wind. An experimental investigation was conducted to observe flux spreading on the receiver panel wall. A lab-scale prototype planar receiver, fabricated using Haynes 230 alloy, was tested under direct concentrated solar radiation using the high-flux solar furnace (HFSF) facility at NREL. The experiment was performed under normal peak radiative heat fluxes ranging from 800 to 1900 kW/m2. A temperature distribution on the panel wall was measured using a thermal imaging camera (FLIR A 6600). To prevent overheating at the receiver front tip, prism-shaped heat shields (Zircar UNIFROM C1) were placed in front of the receiver, and their influence on flux spreading was also studied. Absorbed flux distribution on the panel wall was modeled using SolTrace. The total solar power and flux distributions delivered from HFSF were determined based on the heliostat mirror optical properties, direct normal irradiance (DNI) on the on-sun testing days, peak flux measurement during the on-sun testing, and shutter/attenuator settings Due to the large incident angles of the solar beam on the panel wall, the angular optical properties of Haynes 230 alloy and Zircar heat shields were incorporated into the model. This flux distribution model was then integrated into a computational fluid dynamics (CFD) simulation to predict the receiver panel wall temperature, which was compared with the experimental measurements. Both prediction and measurements identified a temperature hotspot at the backside of the panel, indicating that the incident solar beam can fully reach to the rear of the receiver. The heat shields positioned at the front of the receiver effectively reduced the excessive temperature rise at the receiver front tip. Overall, the temperature was well distributed over the panel wall, with a minor hotspot at the back of the receiver. The model slightly overpredicted the temperature, possibly due to discrepancies in optical properties of the panel and an underprediction of thermal loss in the receiver. The advancement of the particle LTPCR offers a viable alternative to open-cavity receivers by addressing particle loss issues. Additionally, it presents a pathway for enabling solar thermochemical processes, extending CSP technology beyond power generation to fuel and chemical production.
14 SOLAR ENERGY↗
An Advanced Cooling Device for Concentrated Photovoltaic Systems
Concentrated photovoltaics (CPV) have the potential to significantly enhance the energy conversion utilization of solar panels and reduce solar generation costs, making them a crucial area of advancement in solar power generation technology. However, the concentration of sunlight can lead to overheating of solar panels, resulting in a notable reduction in both the efficiency of solar power generation and the lifespan of the panels. This challenge remains the predominant technical hurdle that hinders the application of concentrated photovoltaic power generation technology. In this study, we propose a new cooling method for concentrated photovoltaic power generation systems via an integrated approach of incorporating Phase-Change Thermal Storage (PCTS) and Thermoelectric Generator (TEG) technology. This new method not only enhances the overall system's electricity generation efficiency but also effectively resolves the technical challenge of concentrated photovoltaic panel overheating issues, ensuring the continuity of concentrated photovoltaic power generation and extending the lifespan of solar panels and their components. In order to make full use of the wasted heat generated by photovoltaic power generation and effectively improve the power generation efficiency of the system, this work developed a phase change heat storage device based on a phase change material. This device uses the temperature difference between day and night to recover wasted heat from photovoltaic power generation. Through integration with the thermoelectric power generation system, thermal energy can be converted into electrical energy. In addition, the Peltier effect of thermoelectric materials is used to construct a photovoltaic panel overheating protection system, which significantly improves the reliability and service life of the system.
14 SOLAR ENERGY↗
Magnetic Materials Research at SRNL
Fig: Rietveld Refinement of room temperature PXRD data for annealed Ce2Fe14B (left panel), (Y0.1Ce1.9)Fe14B (middle panel), and (Lu0.1Ce1.90)Fe14B (right panel) alloys. All annealed alloys plotted are composed primarily of Ce2Fe14B phase with small α-Fe impurities. Vertical blue ticks correspond to the position of the calculated Bragg peaks of all phases (from top to bottom, 2-14-1 and α-Fe). Fig: (Left Panel) Field dependent magnetization measurements on aligned powder with the magnetic field applied along the easy direction for annealed Ce2Fe14B and (YxCe2-x)Fe14B (x=0.1, 0.2, 0.3, 0.4, 0.5) alloys. (Middle Panel) Field dependent magnetization measurements on aligned powder with the magnetic field applied along the hard direction for annealed Ce2Fe14B and (YxCe2-x)Fe14B (x=0.1, 0.2, 0.3, 0.4, 0.5) alloys. (Right Panel) The saturation magnetization of Ce2Fe14B and (YxCe2-x)Fe14B (x=0.1, 0.2, 0.3, 0.4, 0.5) alloys as determined from easy axis field dependent magnetization measurements.
Bretana, Alex↗
Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy
Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.
99 GENERAL AND MISCELLANEOUS↗
An Advanced Cooling Device for Concentrated Photovoltaic Systems
Concentrated photovoltaics (CPV) have the potential to significantly enhance the energy conversion utilization of solar panels and reduce solar generation costs, making them a crucial area of advancement in solar power generation technology. However, the concentration of sunlight can lead to overheating of solar panels, resulting in a notable reduction in both the efficiency of solar power generation and the lifespan of the panels. This challenge remains the predominant technical hurdle that hinders the application of concentrated photovoltaic power generation technology. In this study, we propose a new cooling method for concentrated photovoltaic power generation systems via an integrated approach of incorporating Phase-Change Thermal Storage (PCTS) and Thermoelectric Generator (TEG) technology. This new method not only enhances the overall system's electricity generation efficiency but also effectively resolves the technical challenge of concentrated photovoltaic panel overheating issues, ensuring the continuity of concentrated photovoltaic power generation and extending the lifespan of solar panels and their components. In order to make full use of the wasted heat generated by photovoltaic power generation and effectively improve the power generation efficiency of the system, this work developed a phase change heat storage device based on a phase change material. This device uses the temperature difference between day and night to recover wasted heat from photovoltaic power generation. Through integration with the thermoelectric power generation system, thermal energy can be converted into electrical energy. In addition, the Peltier effect of thermoelectric materials is used to construct a photovoltaic panel overheating protection system, which significantly improves the reliability and service life of the system.
Gou, Yimeng↗
Primary Pump Motor Area - Transfer Fan Replacement PLC Design
My poster is about a project that I have worked on in my time at ATR as an intern. The Heating and Ventilation Control Panel (HVB-1) controls thirty-five heating and ventilation fans within the Advanced Test Reactor. This control panel needs replacement, as many of the components inside the existing panel are becoming old and degrading. In preparation for this replacement effort, concepts and component identification for the new control panel needed to be developed. Instead of replacing the new panel with replacement mechanical components, a Programmable Logic Controller (PLC) is proposed as a solution. Although multiple fans are associated with this panel, my poster focuses on the replacement design for the Primary Pump Motor Area Transfer Fan. This will provide an example of how the entire cabinet may be upgraded.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
High Velocity Joining of Multi-material Stacks Containing 3rd Generation Advanced High-Strength Stainless Steel and Aluminum Extrusion and Casting (Abstract)
Advanced lightweight materials, including multi-phase steels, aluminum extrusions and aluminum castings, have increasingly replaced mild steel to meet original equipment manufacturer (OEM) demand for increased fuel economy and crash-safety requirements. Third Generation (Gen 3) AHSS provides a superior combination of strength and ductility for crash energy management components in the vehicle body-in-white (BIW). Aluminum extrusions are widely used for bumper, door rocker panel, cradle and battery frame applications. Aluminum castings are increasingly being used in electric vehicles to provide part consolidation, weight saving and increased driving range. Rocker panels are, for example, an important component of the battery electric vehicle (BEV) body structure. The rocker panel serves several purposes, including structural support, crash resistance, protection for the vehicle's underbody and battery tray, and contributing to the overall aesthetics. In order to reduce weight, rocker panels are usually constructed using outer panels consisting of 3rd generation advanced high strength steels (AHSS) and an inner multicell aluminum extrusion structure for energy absorption which protects the batteries in a crash event. It is well known, however, that these material combinations provide significant challenges for joining and are susceptible to liquid metal embrittlement and loss of strength. The overall goal is to find a solution that addresses these challenges in order to produce multi-material vehicle components with reduced weight and minimal galvanic and recyclability issues. The approach being proposed here is to utilize a novel high velocity (HiVe) riveting and clinching technique recently demonstrated by Pacific Northwest National Laboratory (PNNL) to join (2T/3T) sheets of aluminum alloys and steel. This process will not only address the aforementioned challenges but also help significantly reduce the joining cycle time. This work will also demonstrate use of HiVe assemblies to be retrofitted to existing body-shop robots thus having minimal impact to existing body shop operations.
36 MATERIALS SCIENCE↗
Modeling Wind in Agrivoltaics and its Impact on Eddy Covariance Flux Measurements
Silicon Ranch is conducting a research study at their 138MW Bancroft Station agrivoltaics site, the largest agrivoltaics research array in the US, in which they are using an eddy covariance flux tower to measure the carbon budget. They are interested in finding out if the presence of the panels changes the effectiveness of these measurements. To investigate this topic, NLR performed numerical simulations of wind through the agrivoltaic array to identify under what environmental conditions (wind speed, wind direction, temperatures) and panel tilt angles the mean wind speeds at the measurement heights are significantly altered by the presence of the solar panels. NLR adapted and used the PVade simulation tool [1] to model wind in Silicon Ranch's agrivoltaic array and found that at the height of the flux tower (6m), the wind speed measured is not significantly altered by the presence of solar panels. The percent difference is less than 4% and is generally greatest during daytime conditions at higher wind speeds and perpendicular wind direction. Closer to the ground, the flow is significantly altered (wind speeds are reduced) by the presence of solar panels and the percent difference increases in strong winds. The work confirmed that eddy covariance flux towers can be used within the context of a solar array field.
14 SOLAR ENERGY↗
Thermally anisotropic building envelope for thermal management: finite element model calibration using field evaluation data
The thermally anisotropic building envelope (TABE) is an active building envelope that redistributes thermal loads in response to weather conditions and building energy demand. Conductive layers throughout the TABE distribute low-grade heat among hydronic loops, altering heat flow direction and intensity. Finite element models of TABE roof and wall panels were developed and calibrated using field evaluation data. The calibration results showed that heat flux differences between the experimental data and finite element models averaged –0.42% and 3.57%, with a maximum mean square error of 1.78 and 3.96 for roof and wall panels, respectively. A reduction in heat flux from the environment to the building living space over the entire testing period (weeks in July/August) was found to be 85% for roof panels and 335% (load reversed) for wall panels. Finally, these results indicate TABE can effectively harness low-grade thermal energy sources to achieve high energy efficiency and promote demand-side management.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Detector alignment for X-ray crystallography using Millepede-II
I describe a method for accurately refining the geometrical parameters of segmented X-ray area detectors on the basis of serial crystallography data, using 'Millepede' – an algorithm created for a very similar problem in high-energy physics. The Millepede method for serial crystallography builds on the approach of Brewster et al. [Acta Cryst. (2018), D74, 877–894], in which the detector parameters are refined simultaneously with the parameters for each individual crystal. This accounts for the mutual dependency between the parameters and thereby avoids the bias and slow convergence problems that have afflicted older approaches in which the deviations between observed and calculated Bragg peak positions were taken directly as the updates for the detector panel positions. The Millepede method uses the special structure of the least-squares normal equations to reduce them to a much smaller form that can be solved very quickly, even compared with the sparse matrix methods used previously. This makes it practical to refine the detector geometry frequently and thereby maintain accurate calibration without specialized alignment campaigns. Tilts of detector panels out of the plane can be reliably refined, as can the overall distance of the detector in the beam direction. With a simulated test case, the new method produced panel shifts within 7% of the correct values with only one iteration, and produced almost exactly correct shifts after a second iteration. A simulated out-of-plane panel rotation was correctly determined to within 0.001°. Applied to experimental data from an X-ray free-electron laser, the method increased the indexable fraction of frames from 30% to 91% in a single iteration, and to 96% after two further iterations. Computing the geometry updates on the basis of 2060 crystals took only 0.819 s on desktop computing hardware, including the time taken to read the required data from disk. The scaling was found to be very close to linear for up to 100 980 sets of crystal parameters, which took only 78.2 s to process under the same conditions. The method has been applied as part of a real-time feedback system at a synchrotron radiation beamline, in which an out-of-plane detector tilt of 0.04° was detected and corrected. Possible further applications are also described here.
Millepede-II↗