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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

System-Level Thermal Management and Reliability of Automotive Electronics: Goals and Opportunities Using Phase-Change Materials

Abstract Electronic packaging for automotive applications are at particular risk of thermomechanical failure due to the naturally harsh conditions it is exposed to. With the rise of electric and hybrid electric vehicles (EVs and HEVs), combined with a desire to miniaturize, the challenge of removing enough heat from electronic devices in automotive vehicles is evolving. This paper closely examines the new challenges in thermal management in various driving environments and aims to classify each existing cooling method in terms of performance. Particular focus is placed upon emerging solutions regarded to hold great potential, such as phase-change materials (PCMs). PCMs have been regarded for some time as a means of transferring heat quickly away from the region with the electronic components and are widely regarded as a possible means of carrying out cooling in large scale from small areas, because of their high latent heat of fusion, high specific heat, temperature stability, and small volume change during phase change, etc. They have already been utilized as a method of passive cooling in electronics in various ways, but their adoption in automotive power electronics, such as in traction inverters, has yet to be fulfilled. A brief discussion is made on some of the potential areas of application and challenges relating to more widespread adoption of PCMs, with reference to a case study using computational model of a commercially available power module used in automotive applications.

Engineering↗
DOE OSTI2024

A Phenomenological Thermal Spray Wall Interaction Modeling Framework Applied to a High Temperature Ignition Assistant Device

Airborne compression ignition engines must operate with reliable ignition systems to achieve proper ignition at every cycle, particularly at high altitudes. Glow-plug-based ignition-assistant (IA) devices can provide the necessary energy to preheat the fuel and ensure ignitability of the fuel-air mixture. Ignitability of liquid sprays can be facilitated via direct impingement onto the hot IA surface, however this comes with adverse effects on the IA durability. Therefore, optimizing an IA’s design requires detailed understanding of the physics of fuel spray impingement of superheated surfaces. While spray impingement on relatively low wall temperatures has been extensively studied and appropriate numerical models have been proposed through the years, fundamental understanding of high-speed liquid spray impingement on superheated walls is still elusive. This work aims to formulate a phenomenological thermal spray-wall interaction framework for modeling the film-boiling-induced heat transfer, atomization, and dispersion of fuel spray droplets impinging onto a superheated IA device. A qualitative comparison of the new phenomenological model is performed against optical experiments from the literature of an F-24 fuel spray injected onto an IA device located 12 mm away from the injector tip. The temperature of the IA was set at 1400 K. The fuel injection pressure was 400 bar, while the ambient gas pressure and temperature were 30 bar and 800 K, respectively. The performance of the phenomenological model is evaluated in comparison with two other state-of-art models from the literature. A qualitative analysis of the different spray and fuel-air mixture characteristics is performed to outline the differences in the predictions offered by the new phenomenological model and the two state-of-art spray-wall interaction models.

droplet dispersion↗
DOE OSTI2024

Coupled Multiphysics Modeling of Lithium-Ion Batteries for Automotive Crashworthiness Applications

Considerable advances have been made in battery safety models, but achieving predictive accuracy across a wide range of conditions continues to be challenging. Interactions between dynamically evolving mechanical, electrical, and thermal state variables make model prediction difficult during mechanical abuse scenarios. In this study, we develop a physics-based modeling approach that allows for choosing between different mechanical and electrochemical models depending on the required level of analysis. We demonstrate the use of this approach to connect cell-level abuse response to electrode-level and particle-level transport phenomena. A pseudo-two-dimensional model and simplified single-particle models are calibrated to electrical-thermal cycling data and applied to mechanically induced short-circuit scenarios to understand how the choice of electrochemical model affects the model prediction under abuse scenarios. These models are implemented using user-defined subroutines on ls-dyna finite element software and can be coupled with existing automotive crash safety models.

analysis and design of components↗
DOE OSTI2015

SU-E-T-183: Clinical Quality Assurance Workflow for Dynamic Tumor Tracking Radiation Dose Delivery

Purpose: One of the most important aspects of implementation of new treatment modalities is an ‘end-to-end’ verification of the treatment process. Radiation treatment based on dynamic tracking of a tumor is highly patient-specific, therefore, special attention should be paid to quality assurance of the treatment delivery. Our goal was to design the clinical workflow that ensures accurate delivery of the planned dose using the Dynamic Target Tracking option of VeroTM (BrainLab,MHI) linac. Methods: A patient simulation is designed to include a pre-treatment session to verify whether the system can reliably track the motion of the implanted marker and build the 4D model of the target motion. The external surrogate and target motion patterns are recorded in the ExactracTM log files. In this work, a spectrum of custom marker and external surrogate motion trajectories closely resembling the patient specific motion patterns was used. 1mm thick/11mm long VisicoilTM marker was placed 15 and 20mm from the center of the spherical tissue equivalent target (centroid to centroid distance) in the 4D motion phantom (CIRSTM). 3D conformal (3 mm block margin) SBRT plans were delivered to 2 moving targets in the phantom: 1) 20mm diameter target that allows ion chamber dose measurement and 2) 25mm target that allows using film to measure CAX dose (GafchromicTM EBT3 used). The measured dose was compared to the iPlanTM TPS results using MonteCarlo algorithm (1% variance, Dose-to-water). Results: On average, film shows 98.9% pass using gamma criterion for 2% and 2mm DTA, 94.3% match for 2% and 1 mm DTA, 98% pass for 1% and 2 mm DTA however only 88% points passing for 1% and 1 mm DTA. Ion chamber measurements agreed with the calculation within 1.5%. Conclusion: The clinical QA workflow was designed for SBRT delivery using real-time tumor tracking on VeroTM linac.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

High energy density picoliter-scale zinc-air microbatteries for colloidal robotics

The recent interest in microscopic autonomous systems, including microrobots, colloidal state machines, and smart dust, has created a need for microscale energy storage and harvesting. However, macroscopic materials for energy storage have noted incompatibilities with microfabrication techniques, creating substantial challenges to realizing microscale energy systems. Here, we photolithographically patterned a microscale zinc/platinum/SU-8 system to generate the highest energy density microbattery at the picoliter (10 −12 liter) scale. The device scavenges ambient or solution-dissolved oxygen for a zinc oxidation reaction, achieving an energy density ranging from 760 to 1070 watt-hours per liter at scales below 100 micrometers lateral and 2 micrometers thickness in size. The parallel nature of photolithography processes allows 10,000 devices per wafer to be released into solution as colloids with energy stored on board. Within a volume of only 2 picoliters each, these primary microbatteries can deliver open circuit voltages of 1.05 ± 0.12 volts, with total energies ranging from 5.5 ± 0.3 to 7.7 ± 1.0 microjoules and a maximum power near 2.7 nanowatts. We demonstrated that such systems can reliably power a micrometer-sized memristor circuit, providing access to nonvolatile memory. We also cycled power to drive the reversible bending of microscale bimorph actuators at 0.05 hertz for mechanical functions of colloidal robots. Additional capabilities, such as powering two distinct nanosensor types and a clock circuit, were also demonstrated. The high energy density, low volume, and simple configuration promise the mass fabrication and adoption of such picoliter zinc-air batteries for micrometer-scale, colloidal robotics with autonomous functions.

Robotics↗
DOE OSTI2023

Performance portable ice-sheet modeling with MALI

High-resolution simulations of polar ice sheets play a crucial role in the ongoing effort to develop more accurate and reliable Earth system models for probabilistic sea-level projections. These simulations often require a massive amount of memory and computation from large supercomputing clusters to provide sufficient accuracy and resolution; therefore, it has become essential to ensure performance on these platforms. Many of today’s supercomputers contain a diverse set of computing architectures and require specific programming interfaces in order to obtain optimal efficiency. In an effort to avoid architecture-specific programming and maintain productivity across platforms, the ice-sheet modeling code known as MPAS-Albany Land Ice (MALI) uses high-level abstractions to integrate Trilinos libraries and the Kokkos programming model for performance portable code across a variety of different architectures. In this article, we analyze the performance portable features of MALI via a performance analysis on current CPU-based and GPU-based supercomputers. The analysis highlights not only the performance portable improvements made in finite element assembly and multigrid preconditioning within MALI with speedups between 1.26 and 1.82x across CPU and GPU architectures but also identifies the need to further improve performance in software coupling and preconditioning on GPUs. We perform a weak scalability study and show that simulations on GPU-based machines perform 1.24–1.92x faster when utilizing the GPUs. The best performance is found in finite element assembly, which achieved a speedup of up to 8.65x and a weak scaling efficiency of 82.6% with GPUs. We additionally describe an automated performance testing framework developed for this code base using a changepoint detection method. The framework is used to make actionable decisions about performance within MALI. We provide several concrete examples of scenarios in which the framework has identified performance regressions, improvements, and algorithm differences over the course of 2 years of development.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2014

Buildings-to-Grid Technical Opportunities: Introduction and Vision

The introduction of smart sensing, metering, and control technology is transforming the nature of our power system from end to end. Enabled by the proliferation of information technology, decision makers—such as utilities and building owners—can see and understand the operation of their systems with unprecedented levels of granularity and detail. Technological advances such as smart thermostats and Phasor Measurement Units, which grant grid operators increased situational awareness, promise tremendous gains in the efficiency and grid-responsiveness of commercial and residential buildings, as well as the overall power system’s reliability and efficiency.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2015

System Study: High-Pressure Safety Injection 1998-2014

This report presents an unreliability evaluation of the high-pressure safety injection system (HPSI) at 69 U.S. commercial nuclear power plants. Demand, run hours, and failure data from fiscal year 1998 through 2014 for selected components were obtained from the Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES). The unreliability results are trended for the most recent 10 year period, while yearly estimates for system unreliability are provided for the entire active period. No statistically significant increasing or decreasing trends were identified in the HPSI results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

System Study: Reactor Core Isolation Cooling 1998-2014

This report presents an unreliability evaluation of the reactor core isolation cooling (RCIC) system at 31 U.S. commercial boiling water reactors. Demand, run hours, and failure data from fiscal year 1998 through 2014 for selected components were obtained from the Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES). The unreliability results are trended for the most recent 10 year period, while yearly estimates for system unreliability are provided for the entire active period. No statistically significant trends were identified in the RCIC results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Impact of Clean Energy R&D on the U.S. Power Sector

The U.S. government, along with other governments, private corporations and organizations, invests significantly in research, development, demonstration and deployment (RDD&D) activities in clean energy technologies, in part to achieve the goal of a clean, secure, and reliable energy system. While specific outcomes and breakthroughs resulting from RDD&D investment are unpredictable, it can be instructive to explore the potential impacts of clean energy RDD&D activities in the power sector and to place those impacts in the context of current and anticipated market trends. This analysis builds on and leverages analysis by the U.S. Department of Energy (DOE) titled “Energy CO 2 Emissions Impacts of Clean Energy Technology Innovation and Policy” (DOE 2017). Similar to DOE (2017), we explore how additional improvements in cost and performance of clean energy technologies could impact the future U.S. energy system; however, unlike the economy-wide modeling used in DOE (2017) our analysis is focused solely on the electricity sector and applies a different and more highly spatially-resolved electric sector model. More specifically, we apply a scenario analysis approach to explore how assumed further advancements in clean electricity technologies would impact power sector generation mix, electricity system costs, and power sector carbon dioxide (CO 2 ) emissions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

Geothermal System Extensions

This material is based upon work supported by the Department of Energy under Award Number DE-EE0000318. The City of Boise operates and maintains the nation’s largest geothermal heating district. Today, 91 buildings are connected, providing space heating to over 5.5 million square feet, domestic water heating, laundry and pool heating, sidewalk snowmelt and other related uses. Approximately 300 million gallons of 177°F geothermal water is pumped annually to buildings and institutions located in downtown Boise. The closed loop system returns all used geothermal water back into the aquifer after heat has been removed via an Injection Well. Water injected back into the aquifer has an average temperature of 115°F. This project expanded the Boise Geothermal Heating District (Geothermal System) to bring geothermal energy to the campus of Boise State University and to the Central Addition Eco-District. In addition, this project also improved the overall system’s reliability and increased the hydraulic capacity.

15 GEOTHERMAL ENERGY↗
DOE OSTI2017

Regulatory Incentives and Disincentives for Utility Investments in Grid Modernization

Electric power is America's most capital-intensive industry, with more than $100 billion invested each year in energy infrastructure. Investment needs are likely to grow as electric utilities make power systems more reliable and resilient, deploy advanced digital technologies, and facilitate new services to meet some consumers' expectations for greater choice and control. But do current regulatory approaches provide the appropriate incentives for grid modernization investments? This report presents three perspectives: -Financial analyst Steve Kihm begins by explaining that any major investor-owned electric utility that wants to raise capital today can do so at a reasonable cost. The question is whether utility managers want to raise capital for grid modernization. Specifically, they look for investments that create the most value for their existing shareholders. In cases where grid modernization investments are not the best choice in terms of shareholder value, Kihm describes shareholder incentive mechanisms that regulators could consider to encourage such investments when they are in the public interest. -From an institutional perspective, Dr. Janice Beecher finds that the traditional rate-base/rate of return regulatory model provides powerful incentives for utilities to pursue investments, cost control, efficiency and even innovation, and it is well suited to the policy objectives of grid modernization. Prudence of grid modernization investments (fair returns) depends on careful evaluation of the specific asset, and any special incentives (bonus returns) should be used only if they promote economic efficiency consistent with the core goals of economic regulation. According to Beecher, realizing the promises of grid modernization depends on effective implementation of the traditional regulatory model and ratemaking tools to serve the public interest. -Conversely, former commissioner and clean energy consultant Ron Lehr says that rapid electric industry changes require a better alignment of utility investment incentives with changes challenging the electricity sector, emerging grid modernization options and benefits, and public policies. For example, investor-owned utilities typically have an incentive to make capital investments, but rarely to employ expense-based solutions, since utilities do not earn profits on expenses. Further, Lehr cites a variety of factors that stand in the way of creating well targeted and well aligned utility incentives, including litigated regulatory processes. These may be a poor choice for finding the right balance among competing interests, establishing rules of prospective application, justifying demonstrations of new technologies and approaches to meeting emerging consumer demands, and keeping pace with rapid change.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

Time-Varying Value of Energy Efficiency in Michigan

Quantifying the time-varying value of energy efficiency is necessary to properly account for all of its benefits and costs and to identify and implement efficiency resources that contribute to a low-cost, reliable electric system. Historically, most quantification of the benefits of efficiency has focused largely on the economic value of annual energy reduction. Due to the lack of statistically representative metered end-use load shape data in Michigan (i.e., the hourly or seasonal timing of electricity savings), the ability to confidently characterize the time-varying value of energy efficiency savings in the state, especially for weather-sensitive measures such as central air conditioning, is limited. Still, electric utilities in Michigan can take advantage of opportunities to incorporate the time-varying value of efficiency into their planning. For example, end-use load research and hourly valuation of efficiency savings can be used for a variety of electricity planning functions, including load forecasting, demand-side management and evaluation, capacity planning, long-term resource planning, renewable energy integration, assessing potential grid modernization investments, establishing rates and pricing, and customer service (KEMA 2012). In addition, accurately calculating the time-varying value of efficiency may help energy efficiency program administrators prioritize existing offerings, set incentive or rebate levels that reflect the full value of efficiency, and design new programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Fracture Toughness Evaluation for Sandia Mock-up Stainless Steel Canister Weldment Using Spiral Notch Torsion Fracture Toughness Test

Many radioactive materials within the nuclear fuel cycle present a significant hazard. Such materials include spent nuclear fuel, high-level waste, legacy waste and other nuclear materials that have no current outlet than storage. These materials are often held in long-term storage as an interim stage within their lifecycle. Lifecycles can include reuse or disposal. Safety and security of spent nuclear fuel (SNF) interim storage installations are very important, due to a great concentration of fission products, actinides and activation products. Stress corrosion cracking of interim storage containers has been identified as a high priority data gap by the Department of Energy. However, little has been done with regards to the canister weld material properties, including the fracture toughness, and their impact on stress corrosion, until recently from Sandia National Laboratory canister mockup program. Furthermore, because no post-weld heat treatment was required, the associated high tensile residual stress within these canister welds can drive the initiation and growth of stress corrosion cracking (SCC) cracks. Thus, the fracture mechanical property, such as fracture toughness, is an essential information to understand the canister weldment fracture resistance behavior and to support mitigation protocol development to counter SCC. In this work, we carried out fracture toughness evaluation on the received mock-up canister weldments from Sandia, using spiral notch torsion fracture test technology. The details of the weldment fracture toughness evaluation program development at ORNL are presented in this progress report. The objective of this research is to collect fracture toughness data on the mock-up canister weldment from Sandia National Laboratory. Data will be collected under quasi-static fracture loading using the Oak Ridge National Laboratory (ORNL) developed Spiral Notch Torsion Test (SNTT) technology carried out on a biaxial tension/torsion tester. These data will be used to support the ongoing SNF dry storage canister modeling activities and to address regulatory issues associated with canister container integrity and the follow-on SNF system transport reliability. SNTT has been a recent breakthrough in measuring fracture toughness for different materials, including metals, ceramics, concrete and polymers composites. Due to its high geometry constraint and unique loading condition, SNTT can be used to measure the fracture toughness with smaller specimens without concern of size effects. The application of SNTT to brittle materials has been proved to be successful. The micro-cracks induced by original notches in brittle materials could ensure crack growth in SNTT samples. Therefore, no fatigue pre-cracks are needed. The application of SNTT to the ductile material to generate valid toughness data will require a test sample with sufficient crack length to increase the sample fracture tip localized constraint. Fatigue pre-crack growth techniques are employed to introduce sharp crack front into the sample. Previously, only rough calculations were applied to estimate the compliance evolution in the SNTT crack growth process; while accurate quantitative descriptions have never been attempted. This generates an urgent need to understand the crack evolution during the SNTT fracture testing process of ductile materials. The newly developed governing equations for SNTT crack growth estimate are used to control the fatigue crack growth to effectively reaching the target crack length. The detailed SNTT approach and its estimated fracture toughness for the as-received Sandia canister weldment and the associated baseline 304 stainless steel are presented in this report. In the past SNTT technology has also been successfully applied to investigate the fracture behavior of X52 and X80 steels and the X52 welded materials used for hydrogen infrastructures. The current study in supporting Sandia SNF Dry Storage Mock-up Canister Program is the first attempt of applying SNTT to the highly ductile stainless steel and the associated weld materials. The SNTT test results indicate that SNTT method is a reliable test approach with good repeatability in applying to SS304 steel and SS304/308 weld material. The estimate JQ upon fracture for the baseline SS304 steel is at 1618 lb/in. The estimate JQ upon fracture for the SS304/308 weld from HAZ and weld specimens are 720 lb/in and 850 lb/in, respectively.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Micro Reactor Instrumentation and Control FY2019 Report

Micro-reactors (i.e., very small transportable or mobile nuclear reactors with a capacity less than 20 MWt) are being developed to supply heat and power for various applications in remote areas, military installations, emergency operations, humanitarian missions, and disaster relief zones. A wide variety of reactor types are under consideration, including sodium-cooled fast reactors, molten salt reactors, light water reactors, very-high-temperature gas reactors, and heat pipe reactors. These miniaturized transportable reactor designs remain largely untested and unproven. System and component testing are needed to demonstrate design safety and system robustness, reliability and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems (Final Report)

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all-ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

03 NATURAL GAS↗
DOE OSTI2019

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems (Final Scientific Report Updated)

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all-ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

36 MATERIALS SCIENCE↗