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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 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Negative stress margins – are they real?

Advances in modeling and simulation, new finite element software, modeling engines and powerful computers are providing opportunities to interrogate designs in a very different manner and in a more detailed approach than ever before. Margins of safety are also often evaluated using local stresses for various design concepts and design parameters quickly once analysis models are defined and developed. This paper suggests that not all the negative margins of safety evaluated are real. The structural areas where negative margins are frequently encountered are often near stress concentrations, point loads and load discontinuities, near locations of stress singularities, in areas having large gradients but with insufficient mesh density, in areas with modeling issues and modeling errors, and in areas with connections and interfaces, in two-dimensional (2D) and three-dimensional (3D) transitions, bolts and bolt modeling, and boundary conditions. Now, more than ever, structural analysts need to examine and interrogate their analysis results and perform basic sanity checks to determine if these negative margins are real.

Raju, Ivatury S.↗
NASA NTRSDate not supplied

Using Digital Image Correlation for Material Testing at Cryogenic Temperatures

Recent efforts were made to parametrize an aluminum alloy at cryogenic temperatures to calibrate finite element models simulating material deformation. Digital image correlation (DIC) was used to measure material properties using front/back strains of specimens during tensile tests. Data acquired from DIC was compared to physical extensometer measurements. Two camera pairs (front and back) were mounted via aluminum extrusion to the exterior of an environmental chamber of a hydraulic test stand. Images were taken through single-pane optical glass windows of the environment chamber. Positive pressure bags encased the cameras, attaching to the perimeter of the glass to keep out moisture and prevent windows from frosting. Figure 1 shows the environmental setup and the camera setup during cryogenic testing. Some of the challenges during testing at cryogenic temperatures include the gaseous flow of liquid nitrogen in the optical path of the mounted cameras, frost buildup on the windows as seen in Figure 1b, and frost on the test coupon. The temperature gradient present during the introduction of liquid nitrogen into the chamber can increase the projection error of images captured of the specimen. Figure 2 shows the estimated projection error from DIC as a function of temperature during the cool down process. This presentation addresses some of the concerns and observations when using DIC for testing at cryogenic temperatures using methods of isolated camera system and techniques for maintaining the glass panel clear from frost.

Joseph Cochran↗
DOE OSTI2017

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Simunovic, Srdjan↗
DOE OSTI2018

New Insights into Shape Memory Alloy Bimorph Actuators Formed by Electron Beam Evaporation

In order to create shape memory alloy (SMA) bimorph microactuators with high-precision features, a novel fabrication process combined with electron beam (E-beam) evaporation, lift-off resist and isotropic XeF2 dry etching method was developed. To examine the effect of E-beam deposition and annealing process on nitinol (NiTi) characteristics, the NiTi thin film samples with different deposition rate and overflow conditions during annealing process were investigated. With the characterizations using scanning electron microscope and x-ray diffraction, the results indicated that low E-beam deposition rate and argon employed annealing process could benefit the formation of NiTi crystalline structure. In addition, SMA bimorph microactuators with high-precision features as small as 5 microns were successfully fabricated. Furthermore, the thermomechanical performance was experimentally verified and compared with finite element analysis simulation results.

36 MATERIALS SCIENCE↗
DOE OSTI2019

HAMT extension for EnergyPlus encompasses moisture sources due to air leakage

As building envelopes become more energy efficient, new buildings are more prone to hygrothermal failure. The combined Heat and Moisture Transfer (HAMT) model in EnergyPlus is able to provide moisture profiles through multiple material layers of an envelope assembly using a coupled, one-dimensional, finite element model simulating the movement and storage of heat and moisture. However, HAMT is currently unable to properly assess the effects of moisture sources inside an assembly to determine impacts on durability, indoor air quality, and energy performance.This paper reviews existing tools for modeling moisture sources due to air leakage and the HAMT model equations in EnergyPlus. A sub-model is then developed that enables air leakage to be applied to a moisture sink/source at an arbitrary location by extending the existing mass transfer equation with a source term that includes water vapor deposit from air flow through an assembly. We demonstrate use of this model, discuss limitations, and make the source code publicly available for external use.

Antretter, Florian↗
DOE OSTI2022

Simple coplanar waveguide resonator mask targeting metal-substrate interface

This white paper presents a single-layer mask, found at https://github.com/Boulder-Cryogenic-Quantum-Testbed/simple-resonator-mask. It is designed for fabrication of superconducting microwave resonators towards 1:1 comparisons of dielectric losses from the metal-substrate interface. Finite-element electromagnetic simulations are used to determine participation ratios of the four major regions of the on-chip devices, as well as to confirm lack of crosstalk between neighboring devices and demonstrate coupling tunability over three orders of magnitude. This mask is intended as an open-source community resource for facilitating precise and accurate comparisons of materials in the single-photon, millikelvin regime.

Kopas, Cameron J.↗
DOE OSTI2023

Exploration of Potential Superconducting Multi-Mode Cavity Architectures for Quantum Computing

This thesis describes the investigation of superconducting multi-mode cavity architecture for superconducting transmon-based quantum computing. The dissertation highlights useful features of radio-frequency cavities used for quantum computing, with a brief discussion on the advantages of superconducting cavities. In the subsequent section, the concept of transmon is introduced and the mechanism of coupling with a cavity is analyzed. Once the foundations of the topic are laid down, the thesis focuses on optimizing a multi-mode superconducting rf cavity design originally developed for high-energy physics applications. Such section articulates in two main parts, the first part concerning the "bare" cavity remake via finite-elements eigenmode simulations using a computer-aided design software called CST Studio Suite®. In the second part, a transmon qubit is physically inserted into the modified cavity to assess the qubit-cavity coupling of the new design. In evaluating said coupling, two distinct analysis methods are used, namely the black-box quantization method and the energy participation ratio method, both implemented using Ansys® High-Frequency Electromagnetic-Field Simulator, or HFSS™. Results from the two evaluations, compared together, show that the optimized design meets the requisites to be used for quantum computing purposes.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Toolpath Optimization of Polymer Composite Additive Manufacturing AM Printed Mold to Improve Performance for Compression Molding Applications

This study explores the optimization of toolpaths for short fiber polymer composite additive manufacturing (AM) printed molds in compression molding applications, an emerging trend driven by advancements in 3D printing technology. AM printed molds offer reduced tooling costs and greater design flexibility, particularly for prototyping and low-volume production. The proposed optimization approach evaluates mold performance using two key metrics: deformation and shape accuracy. Multiple toolpaths are generated, and finite element (FE) simulations capture fiber orientation and material properties, which are then integrated into a mechanical performance model. Shape accuracy is assessed by comparing the deformed mold shape with the original using surface normals as a descriptor. The analysis identifies the toolpath that delivers the best overall performance, establishing it as the most suitable option for achieving optimal mold characteristics in compression molding applications.

Limaye, Madhura [ORNL]↗
DOE OSTI2024

Review of recent activities with MOOSE, an open-source finite element & finite volume multi-fidelity simulation framework

Modeling and simulation are an increasing part of engineering. This is undoubtedly driven by the high costs of constructing experimental facilities, but also enabled by the exponential increase in computing powers over the last decades, which allows computational models to be closer than ever to reality. One of the main drivers for the development of MOOSE is supporting advanced nuclear reactor simulations. A challenging aspect of modeling advanced nuclear reactors is the plurality of physics involved, including neutronics, thermal hydraulics and fuel performance. These physics are all coupled to some extent and are generally solved in a sequential but iterative fashion. The United States (U.S.) national laboratories have been developing MOOSE, an open source multiphysics framework since its inception at the Idaho National Laboratory (INL) in 2008. This framework enables seamless coupling of multiphysics simulations and facilitates the implementation of new physics and material governing laws. It is continuously expanded with novel numerical methods and new pre-implemented physics module. Numerous applications, developed within the Department of Energy (DOE) laboratories, academia, and industry, including outside of nuclear engineering, have been developed to study specialized physics problems. International collaborations are welcome on this open-source modeling and simulation project.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Broad frequency tuning of a Nb$_{3}$Sn superconducting microwave cavity for dark matter searches

We demonstrate a novel broad-frequency tuning mechanism for superconducting microwave cavities designed for dark matter searches. Using a Nb$_3$Sn-coated cigar-shaped cavity operating at approximately 9 GHz, we achieve continuous frequency tuning exceeding 1 GHz by mechanically separating the two cavity halves: a "tuning-by-opening" technique. Finite-element method simulations predict that radiative losses do not degrade the quality factor even for large openings, as a closed cavity with an intrinsic quality factor of $10^7$ maintains this value for apertures up to 9 mm, corresponding to a tuning range from 9.0 to 7.5 GHz. Experimental validation using both copper ring spacers and a continuous sliding mechanism confirms $Q_0$ values exceeding the dark matter quality factor across the entire explored frequency range, despite mechanical imperfections and film non-uniformities. This tuning approach avoids inserting elements into the resonant volume, making it particularly suitable for high-Q superconducting cavities in axion haloscope experiments and readily applicable to REBCO-based implementations capable of operating in multi-tesla magnetic fields.

Maiello, D. [Padua U.; INFN, Padua] (ORCID:0009000↗
DOE OSTI2026

In-Situ Magnetic Field Reconstruction in the MAGIS-100 Experiment

Long-baseline atom interferometers such as the Matter-wave Atomic Gradiometer Interferometric Sensor (MAGIS-100) require stringent control and continuous characterization of background magnetic fields and spatial gradients to prevent systemic phase shifts that mimic ultralight dark matter or gravitational wave signatures. Because direct sensor placement within the ultra-high vacuum beam pipe is infeasible, in-situ magnetic field monitoring relies on external sensor arrays situated in the surrounding annular region. This work demonstrates a field reconstruction framework for a 5.3-meter MAGIS-100 modular section using finite-element Opera simulations. Transverse magnetic fields are expanded using a cylindrical multipole framework as informed by Fermilab’s Muon g-2 experiment, with magnetometer array configurations optimized via Fisher information matrix D-optimality. Inverting external sensor readings through a Gauss-Newton scheme recovers interior tube fields across distinct axial positions. In the discontinuity-averse uniform region (slice pair P4), the model achieves sub-noise-floor performance with a cross-validated root-mean-square error (RMSE) of $6.7227 \times 10^{-4}\text{ A/m}$ ($0.845\times$ sensor noise floor) and an interior field coefficient of variation of $1.71\%$. An elbow criterion in the Fisher bounds establishes $n_{\text{max}} = 2$ as the optimal multipole truncation order to prevent noise amplification from over-parameterization, with $n_{\text{max}} = 3$ (sextupole) order chosen for analysis to demonstrate further complexity and cross-pair comparison. Furthermore, analytical differentiation of the fitted multipole coefficients yields dense spatial maps of the transverse Jacobian gradient matrix $\nabla \mathbf{H}$ along with propagated $1\sigma$ uncertainty bounds across the beam region ($r \le 2.75\text{ in}$). This operational framework confirms that external magnetometer arrays can reliably monitor magnetic field uniformity and spatial gradients along the 100-meter flight path given appropriate sampling for any complexity order.

Appleby, Darwin [William Rainey Harper Coll.; Ferm↗
DOE OSTI2016

Determination of the mechanical properties of blisters by nanoindentation

In light-water reactors, a zirconium oxide layer will be formed at the outer surface of the fuel cladding as a consequence of the chemical reaction which takes place between zirconium and the cooling water. This zirconium oxide layer is a good thermal insulator, but at some point, it may spall-out. As a consequence, a cold spot will be formed at the outer surface of the cladding. In this situation, the hydrogen will quickly migrate to this spot to form a highly-enriched hydride zone, known as blister. In this work, an experimental procedure has been devised to produce blisters with a similar shape to the ones reported in the literature for irradiated cladding with severe hydriding. Nano-indentation tests were performed on blisters prepared in laboratory. A numerical simulation by the finite element method was developed to fit the load versus penetration depth data from the aforementioned nano-indentation tests. By means of an inverse process which combines experimental data and numerical simulations, the constitutive equation of the blister was determined. The process has been used to calculate the plastic stress-strain curve of the blister under study at room temperature. The results show an almost perfect numerical fitting of the experimental data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2019

X-57 60kW Permanent Magnet Synchronous Cruise Motor Finite Element Electromagnetic Modeling

The X-57 60kW Permanent Magnet Synchronous Motor for cruise applications was modeled utilizing a two-dimensional electromagnetics simulation software called Finite Element Method Magnets (FEMM, D. Meeker). Through FEMM, the simulated induction and torque characteristics of the X-57 PMSM were obtained. These parameters and other values were compared to actual static laboratory measurements. A three-dimensional electromagnetic model of the X-57 cruise motor was created utilizing OperaFEA (Dassault Systemes SE, Velizy-Villacoublay, France). Torque, RPM, power, resistance, and inductance characteristics were examined along with establishing work to begin examining heat flow and heat dissipation for efficiency purposes.

Marrufo, Marco↗
DOE OSTI2019

Continuum Modeling of Inductor Magnetic Hysteresis and Eddy Currents in Resonant Circuits

This paper presents a high-fidelity finite-element modeling technique for magnetic hysteresis and eddy current losses in toroid inductors. The method is based on the separation of ferromagnetic loss characteristics into two components: a quasi-static hysteresis component and a dynamic eddy current component. The Preisach model is used to describe the quasi-static magnetic hysteresis behavior of the core, providing strong guarantees on the reproducibility of the experimentally measured characteristics. This model is used to represent the magnetic field constitutive relationships within a finite-element framework combining the effects of hysteresis and eddy currents in a unified dynamic simulation. The finite-element model of the toroid is used as a high-order inductor model coupled to a resonant circuit simulation. The modeling technique is validated through experimental measurements on two different series RLC circuits. The first circuit is based on an M19 electrical steel toroid having resonant frequency near 200 Hz. The second circuit is based on a T38 ferrite toroid having a resonant frequency near 10 kHz. The models agree closely with the measured voltages, currents, and losses. The models also successfully predict discontinuities in the measured frequency responses due to the existence of bistable operating regimes.

42 ENGINEERING↗
DOE OSTI2016

Fragmentation Prediction for a Brittle Ceramic: a Two-Scale Model Approach

Glass and oxide-ceramic radioactive material forms (e.g., PuO{sub 2}) are susceptible to brittle fracture during handling and transportation. Fracture of these materials may result in the generation of fragments small enough to become airborne, and thus easily dispersed and inhaled. Entrainment and dispersal of particles with dimensions less than 10 μm is generally anticipated under normal aerodynamic conditions. The assessment of the risk to the public and the environment from these materials due to events resulting in their fracture is based on the determination of the source term for environmental release. This source term is typically quantified by an airborne release fraction (ARF) and a respirable fraction (RF) of material generated by a given event. While the recommended empirical bounding values prove satisfactory to comply with the regulatory process for handling and transportation of these materials, they are based on test data for only a few materials subjected to a limited range of loading conditions. Because the final state of fragmentation (in terms of the size and distribution of fragments) is strongly dependent not only on the properties of the material and the energetic loading conditions that lead to breakup, but also on the many intrinsic length scales associated with fragmentation, it is difficult to precisely predict fragmentation characteristics for other brittle solid wastes forms subjected to a wider range of loading conditions based on the test data alone. The purpose of this manuscript is to present a two-scale modeling approach that may be used to simulate the dynamic fragmentation of brittle solid radioactive material forms subjected to general loading and boundary conditions. The method provides the resulting fragment characteristics (average size and size distribution) across the entire fragment range of interest. At the macro-scale, the approach uses a gradient damage elastic continuum mechanics material model within a finite element framework to simulate dynamic fracture under general loading and boundary conditions. Results from the macroscopic calculations are passed to a one-dimensional (1-D) lower length scale model that incorporates the relevant fine scale effects to determine the micro-scale fragmentation. This 1-D micro-scale fragmentation model simulates the internal crack nucleation and opening processes to predict the average fragment size and the fragment size distribution as a function of the material properties, loading conditions, and microscopic characteristic length scale of the material. Results from the lower length scale model are then combined with the macro-scale model fragmentation information to determine the resulting fragment size distribution spanning both length scales. This two-scale model has been exercised on a representative problem drawn from experimental studies, consisting of an impact of a falling weight onto a brittle ceramic. (authors)

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2019

HTS Transformer Windings Design Using Distributive Ratios for Minimization of Short Circuit Forces

High-temperature superconducting (HTS) transformers have a promising feature in reduction of total weight, total size, and the losses of large-scale distribution transformers. However, the lower leakage reactance of HTS transformers results in a higher short-circuit fault currents and electromagnetic forces. Therefore, optimization of short-circuit electromagnetic forces is one of the crucial aspects in the design of HTS transformers. In this paper, a novel analytical method is proposed for determination of optimum distributive ratios resulting in minimization of these forces for asymmetrical multi-segment windings of an HTS transformer. Employing these distributive ratios, radial and axial components of short-circuit electromagnetic forces in an HTS transformer are significantly reduced. Two- and three-dimensional (2D and 3D) finite element method (FEM) simulations are employed to verify the analytical method results.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗