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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Al–W gradient density materials—Processing and dynamic ramp compression

Materials with high-density gradients are desired for controlling loading paths in dynamic compression, important for studying material properties in extreme conditions and inertial confinement fusion. The large density difference between Al and W makes them ideal choices for producing gradient density materials, but their extremely different melting temperatures make them challenging to fabricate simultaneously. We report a method for producing Al–W porosity-free materials with a fourfold increase in density (2.7–11 g/cm 3 ) across the composition range, from Al-rich to W-rich, without intermetallic phase formation. This was achieved by understanding the aluminum-dominated densification behavior and examining the influence of pressure and temperature on the densification of Al–W composites. Dynamic compression experiments conducted with the Al–W gradient density material produced shock ramp compressions as expected based on the designed composition, and the performed hydrodynamics simulations showed excellent agreement with experimental results. The results demonstrate that current activated pressure-assisted densification allows for the easy and rapid fabrication of gradient density materials with significant density gradients and tailored compositions, facilitating precise control of the loading paths. These materials have the potential to create customized pressure drives for advancing the fields of material science in extreme environments and dynamic compression.

Alloys↗

DOE OSTI2024

Consumer Benefits of Clean Energy: The resilience value of residential solar + storage systems in the continental U.S.

Meeting national and state decarbonization goals requires a transition to clean energy technologies. Energy efficiency, demand flexibility, renewable energy and storage can reduce consumers’ electricity bills, lower total electricity system costs, and provide health and resilience benefits. Berkeley Lab developed a series of briefs that explore these consumer benefits of a clean energy transition. Clean energy resources that are located behind the meter have the potential to benefit the hosting customers by providing affordability, environmental, and reliability and resilience value. Solar plus storage systems (PVESS) are clean energy resources that can supply backup power without requiring fuel resupply or increasing local emissions. This report examines the regional value of PVESS for resilience by calculating a benefit-cost ratio (BCR) that considers the annual resiliency benefits of PVESS and the annualized cost of the investment. In addition, we estimate the expected technical mitigation potential of PVESS systems at the county-level to these expected events, and characterize the customer interruption costs by determining the value of lost load at the state level.

14 SOLAR ENERGY↗

NASA NTRS2021

An Autonomous Vault-Building Robot System for Creating Spanning Structures

Research in autonomous robots for construction has largely focused on ground-based robots whose reach constrains the size of what they can build, or on climbing or aerial robots that build solid or unroofed structures. Autonomous construction of larger, multistory buildings, or bridges spanning unsupported distances, would require robots that build sturdy structures supporting their own weight. In this paper, we present VaultBot, a system of autonomous robots that build a load-bearing spanning vault using identical modular blocks. The custom blocks employ mechanical and other features to facilitate robotic manipulation and locomotion, and can be removed from and replaced in an assembled structure as a way of repairing damage. We characterize the system's performance and failure modes, and demonstrate reliable autonomous assembly for a structure composed of 46 blocks. Blocks can be made collapsible and deployable as a way of reducing mass and volume that must be transported to a construction site. Such a system could be used to help enable construction of protective shelters in challenging environments, such as disaster relief scenarios, arctic settings, or extraterrestrial habitats.

Nathan Melenbrink↗

DOE OSTI2025

Business Models for Scaling Demand Flexibility Volume I – Value proposition characteristics, challenges, and lessons learned from U.S. programs

Load growth at the grid edge is driving increased attention to the distribution system and its ability to enable customer technology adoption in an affordable and timely manner. Key industry stakeholders, including electric utilities and regulators, can benefit from strategies to manage and balance customer needs with infrastructure investments, such as demand flexibility. This report focuses on demand flexibility—the ability to reduce, shift, shed, generate, or modulate loads in response to building and grid needs—to reduce the need for costly grid upgrades by deferring investment needs and increase system reliability by shifting electricity usage during periods of high risk. Specifically, we focus on the emerging characteristics of business models for demand flexibility as a framework to understand how demand flexibility programs generate value. In this report, we focus on demand flexibility value propositions, which provide information on value creation and describe how programs deliver clear benefits that address customer and grid needs. This report discusses the role of value propositions in demand flexibility programs, provides an overview of value propositions for a range of demand flexibility stakeholders, identifies existing challenges to establishing an effective value proposition, and describes lessons learned. This report is part of a series that includes reports on customer relationship management strategies, stakeholder ecosystem management, and program life cycle.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Business Models for Scaling Demand Flexibility Volume III – Stakeholder ecosystem management challenges, and lessons learned from U.S. programs

Load growth at the grid edge is driving increased attention to the distribution system and its ability to enable customer technology adoption in an affordable and timely manner. Key industry stakeholders, including electric utilities and regulators, can benefit from strategies to manage and balance customer needs with infrastructure investments, such as demand flexibility. This report focuses on demand flexibility—the ability to reduce, shift, shed, generate, or modulate loads in response to building and grid needs—to reduce the need for costly grid upgrades by deferring investment needs and increase system reliability by shifting electricity usage during periods of high risk. Specifically, we focus on the emerging characteristics of business models for demand flexibility as a framework to understand how demand flexibility programs generate value. In this report, we focus on demand flexibility program stakeholder ecosystem management strategies, which provide information on value delivery and describe how program implementers leverage partner capabilities and collaborate to deliver customer and grid benefits. This report discusses the role of stakeholder ecosystem management in demand flexibility programs, identifies existing challenges to effective stakeholder management, and describes lessons learned. This report is part of a series that includes reports on value propositions, customer relationship management strategies, and program life cycle.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Business Models for Scaling Demand Flexibility Volume IV – Program life cycle challenges and lessons learned from U.S. programs

Load growth at the grid edge is driving increased attention to the distribution system and its ability to enable customer technology adoption in an affordable and timely manner. Key industry stakeholders, including electric utilities and regulators, can benefit from strategies to manage and balance customer needs with infrastructure investments, such as demand flexibility. This report focuses on demand flexibility—the ability to reduce, shift, shed, generate, or modulate loads in response to building and grid needs—to reduce the need for costly grid upgrades by deferring investment needs and increase system reliability by shifting electricity usage during periods of high risk. Specifically, we focus on the emerging characteristics of business models for demand flexibility as a framework to understand how demand flexibility programs generate value. In this report, we focus on the life cycle of demand flexibility programs, which provides information on value creation and describes the various deployment phases program implementers navigate from initial program conceptualization through to program expansion and replication to new customer segments and regions. This report characterizes the key phases of the demand flexibility program life cycle, identifies existing challenges across the program deployment phases, and describes lessons learned. This report is part of a series that includes reports on customer relationship management strategies, stakeholder ecosystem management, and program life cycle.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2005

FastScript3D - A Companion to Java 3D

FastScript3D is a computer program, written in the Java 3D(TM) programming language, that establishes an alternative language that helps users who lack expertise in Java 3D to use Java 3D for constructing three-dimensional (3D)-appearing graphics. The FastScript3D language provides a set of simple, intuitive, one-line text-string commands for creating, controlling, and animating 3D models. The first word in a string is the name of a command; the rest of the string contains the data arguments for the command. The commands can also be used as an aid to learning Java 3D. Developers can extend the language by adding custom text-string commands. The commands can define new 3D objects or load representations of 3D objects from files in formats compatible with such other software systems as X3D. The text strings can be easily integrated into other languages. FastScript3D facilitates communication between scripting languages [which enable programming of hyper-text markup language (HTML) documents to interact with users] and Java 3D. The FastScript3D language can be extended and customized on both the scripting side and the Java 3D side.

Koenig, Patti↗

DOE OSTI2024

Commercialization of Distribution System Load Modeling Tool for Improved DER Interconnection Studies

Residential and commercial buildings have huge potential to contribute value to improve grid resilience by participating grid services. To reveal the significant value, it is critical to estimate the grid service capability from these buildings. Unlike the large-scale distributed energy resources such as wind and solar farms, those buildings need to participate grid services in aggregation, not by individual. Therefore, it is important to appropriately group buildings for aggregation. The load profiles in the same group will have similar characteristics at the same time step, so grid operators can send the grid service signal to the customer group with a higher chance to respond at that time step. In this paper, we develop a load profile clustering method to classify the building-level load profiles for grid service capability estimation. In our two-step clustering approach, we first calculate the total load consumption for each building, clustering the load profiles based on energy consumption level. Then, we further cluster the load profiles in each energy cluster based on the load shape. The parameter selection for each clustering step is discussed. The proposed method is applied on actual building-level load profiles, and the results have proved the effectiveness of this method.

14 SOLAR ENERGY↗

NASA NTRS2012

Aerospace Threaded Fastener Strength in Combined Shear and Tension Loading

A test program was initiated by Marshall Space Flight Center and sponsored by the NASA Engineering and Safety Center to characterize the failure behavior of a typical high-strength aerospace threaded fastener under a range of shear to tension loading ratios for both a nut and an insert configuration where the shear plane passes through the body and threads, respectively. The testing was performed with a customized test fixture designed to test a bolt with a single shear plane at a discrete range of loading angles. The results provide data to compare against existing combined loading failure criteria and to quantify the bolt strength when the shear plane passes through the threads.

Threaded fastener↗

NASA NTRS2011

Shuttle Program Loads Integration: Going From Concept to Operations and Staying Successful

From the beginning of the Shuttle Program to its end, integrated loads and dynamics analyses and tests have been critical in shaping the vehicle design and operational decisions for NASA and its customers. Starting with scaled models and simple mathematical simulations of the structural dynamics, engineers defined the required structural stiffness and predicted the limit loads for each element of the system. Early structural tests provided reasonable confidence that the models and predictions were good. The first launch of the Space Shuttle brought surprises, though, when the ignition overpressure event caused a forward fuel tank support strut to buckle, among several unexpected effects. The launch pad and other ground equipment became an integral part of the system integration, especially where the acoustic and pressure environments of ignition and lift-off were concerned. Following the Challenger accident, operating limits were changed in response to new understandings of how the integrated system performed. Controlling loads while maximizing performance was a key tenet of the Performance Enhancement design process, which enabled construction of the International Space Station. During the return to flight after the Columbia accident, engineers grew to understand that loads during the roll maneuver were also important to the vehicle s structural margin and life. At this point the crawler transport from the Vehicle Assembly Building to the launch pad also became a part of the integrated loads analysis. Even in the last years of the Space Shuttle Program, new data still provided interesting insights into this complicated and fascinating spaceship. This paper will present some examples of the important findings by the team of specialists that supported the Integrated Loads and Dynamics Panel for the Space Shuttle Program.

Bernstein, Karen↗

DOE OSTI2024

Heat Recovery System for Domestic Dishwashers (Final Report)

The objectives of this project were to enable commercialization of a patent-pending technology for unprecedented dishwasher energy savings and non-energy consumer benefits. Specific objectives were to (1) provide customer-requested features of more thorough drying, (2) reduce kitchen humidity load (75% target reduction in water vapor released by the dishwasher), (3) introduce the lowest energy consumption domestic dishwasher on the market with 30% less energy consumption than that of the current best in market, and (4) maintain high cleaning performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Feasibility of an Accelerometer-Based Structural Health Monitoring System for the LANL Blast Tube

A modeling- and simulation-based study was conducted on the feasibility of implementing an accelerometer-based SHM system on the Los Alamos National Laboratory blast tube. A blast tube experiment was modeled using the Abaqus explicit finite element solver. A custom user subroutine was written to apply test-like pressure loading to the inside surface of the blast tube. The subroutine applies analytically defined pressure loads derived from tracer output taken from a Compressible Flow Computational Fluid Dynamics Solver model of the blast tube. Five unique versions of the model were created: an undamaged reference model at 65°F was used as the baseline and compared to equivalent models at 10°F and 100°F. These three models were compared to models with small damage at the reference temperature. The two types of damage considered were a radial (circumferential) crack in the main tube body and a longitudinal crack in the supports. Acceleration outputs were extracted from accelerometer bodies included in the model and were post processed using a variety of standard SHM techniques. Different potential features signaling failure were extracted and compared using statistical methods in the time and frequency domains. A method was identified that clearly shows that differences in structural response resulting from the modeled damage can be differentiated from the structural response resulting from changing environmental conditions. However, the amount of damage applied to create observable differences in the accelerometer data was so large that simpler methods of damage detection would be more cost effective in locating damage.

42 ENGINEERING↗

NASA NTRS1973

Some extemporaneous comments on our experiences with towers for wind generators

A wind generator tower must be designed to withstand fatigue forces and gust winds loads. Optimum tower height depends on the energy cost to the customer because an increase in height results in an increase in the cost of the plant. It is suggested that costs are minimum for the shortest tower possible and that the rotor should be as large as possible.

Hutter, U.↗

NASA NTRS1979

Lattice panels with high structural efficiency

By orienting strips for maximum strength, composite lattice panel is nearly as strong as "conventional" composite panels. They can be custom-tailored for various applications and also be useful in moderately loaded structures.

Mikulas, M. M., Jr.↗

NASA NTRS2013

RF Reference Switch for Spaceflight Radiometer Calibration

The goal of this technology is to provide improved calibration and measurement sensitivity to the Soil Moisture Active Passive Mission (SMAP) radiometer. While RF switches have been used in the past to calibrate microwave radiometers, the switch used on SMAP employs several techniques uniquely tailored to the instrument requirements and passive remote-sensing in general to improve radiometer performance. Measurement error and sensitivity are improved by employing techniques to reduce thermal gradients within the device, reduce insertion loss during antenna observations, increase insertion loss temporal stability, and increase rejection of radar and RFI (radio-frequency interference) signals during calibration. The two legs of the single-pole double-throw reference switch employ three PIN diodes per leg in a parallel-shunt configuration to minimize insertion loss and increase stability while exceeding rejection requirements at 1,413 MHz. The high-speed packaged diodes are selected to minimize junction capacitance and resistance while ensuring the parallel devices have very similar I-V curves. Switch rejection is improved by adding high-impedance quarter-wave tapers before and after the diodes, along with replacing the ground via of one diode per leg with an open circuit stub. Errors due to thermal gradients in the switch are reduced by embedding the 50-ohm reference load within the switch, along with using a 0.25-in. (approximately equal to 0.6-cm) aluminum prebacked substrate. Previous spaceflight microwave radiometers did not embed the reference load and thermocouple directly within the calibration switch. In doing so, the SMAP switch reduces error caused by thermal gradients between the load and switch. Thermal issues are further reduced by moving the custom, highspeed regulated driver circuit to a physically separate PWB (printed wiring board). Regarding RF performance, previous spaceflight reference switches have not employed high-impedance tapers to improve rejection. The use of open-circuit stubs instead of a via to provide an improved RF short is unique to this design. The stubs are easily tunable to provide high rejection at specific frequencies while maintaining very low insertion loss in-band.

Knuble, Joseph↗

NASA NTRS2013

Comparative Study of Vibration Condition Indicators for Detecting Cracks in Spur Gears

This paper reports the results of an empirical study on the tooth breakage failure mode in spur gears. Of four dominant gear failure modes (breakage, wear, pitting, and scoring), tooth breakage is the most precipitous and often leads to catastrophic failures. The cracks were initiated using a fatigue tester and a custom-designed single-tooth bending fixture to simulate over-load conditions, instead of traditional notching using wire electrical discharge machining (EDM). The cracks were then propagated on a dynamometer. The ground truth of damage level during crack propagation was monitored with crack-propagation sensors. Ten crack propagations have been performed to compare the existing condition indicators (CIs) with respect to their: ability to detect a crack, ability to assess the damage, and sensitivity to sensor placement. Of more than thirty computed CIs, this paper compares five commonly used: raw RMS, FM0, NA4, raw kurtosis, and NP4. The performance of combined CIs was also investigated, using linear, logistic, and boosted regression trees based feature fusion.

Nanadic, Nenad↗

DOE OSTI2024

The resilience value of residential solar + storage systems in the continental U.S.

Abstract Behind the meter rooftop solar plus storage (PVESS) has the potential to benefit the hosting customers by providing affordability, environmental, and reliability and resilience value. Whereas the bill reduction and environmental benefits of PVESS are well studied, its monetary resilience benefits are less understood. The increasing trend of power interruptions driven by extreme weather events heightens the need to understand these benefits. This study leverages various publicly available datasets to perform a cost benefit analysis of adding to determine the resilience value of PVESS for a typical single family home in each county in the continental U.S. We find that PVESS is very effective to technically mitigate interruptions across the country. However, the monetary benefits in the base case only cover about 14% of battery costs, with no county exceeding 60%. This is somewhat expected, given that PVESS provide other monetary benefits that are not part of this analysis. Through sensitivities, we find that higher frequency of extreme weather events roughly triples the resilience value of PVESS and that higher values of lost load double the same metric. Our sensitivity analysis shows that the benefit cost ratio of PVESS for customers living in areas with higher-than-average frequency of long duration interruptions and value of lost load is already above one even without considering other value streams. We conclude with recommendations that regulators and utilities could implement to enable customers to calculate and capture the resilience value of PVESS more efficiently.

Baik, Sunhee↗

DOE OSTI2026

Data-Driven Modeling of High-Resolution Residential Load Profiles Using Low-Resolution Smart Meter Measurements

Accurate and high-resolution residential load profiles are essential for power system modeling, demand response planning, and effective grid operation. As the energy sector moves towards a more actively managed distribution system, the ability to understand residential energy consumption at a minute-by-minute scale becomes increasingly critical. High-resolution load profiles provide key insights into demand patterns and user behavior, enabling grid operators to design more effective energy solutions; however, residential load measurements in the field are typically recorded at low resolutions, such as 15-60 minutes, which makes it hard to study the characteristics of different residential customers. This paper addresses these challenges by introducing a data-driven approach to generate realistic, high-resolution residential load profiles based on lowre-solution measurements and weather information. The proposed method retains the key features of the actual residential load measurements while offering appliance-level energy consumption details for each residential building. The results demonstrate the effectiveness of the proposed load profile generator, proving its capability to support utilities in optimizing residential energy management and ensuring a more reliable and resilient grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗