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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 91 records · Page 5

The Si ribbon crystal for the solar battery using the horizontal pull method

A method utilizing a device to spray noble gases to cool the site of silicon crystal growth is described. The salient points are: (1) soft and uniform cooling was possible, (2) the length of the boundary surface of growth along the growth direction was made long over a wide width compared to the thickness, and (3) this made it possible to effectively remove the heat produced from solification. By using forced gas spraying on the solution surface in contact with the points of crystal growth, growth at the points of growth is enhanced and the rate of growth is speeded up.

Norifuji, H.↗

Thermal Reservoir Networks for Modularly Expandable Thermal Microgrids

The Department of Defense (DoD) faces the substantial challenge of cost-effectively retrofitting one to two installations per month, each comprising approximately 1,000 buildings, to improve resilience, reduce energy consumption, and enhance energy supply security. Achieving these objectives requires optimal system selection and effective risk mitigation during system integration. To address this need, we introduce Platform-Based Design (PBD), a structured, hierarchical methodology adapted from other industrial sectors to the domain of energy system retrofits. We demonstrate the effectiveness of PBD through a techno-economic feasibility study comparing geothermal-coupled thermal energy networks (TENs) with conventional energy systems for heating, cooling, and powering 17 buildings at Joint Base Andrews (JBA) in Maryland. Our analysis illustrates that the PBD approach enables rigorous, data-driven, sequential decision making, resulting in a family of Pareto-optimal systems, among which the TEN emerged as the most promising solution. The selected TEN design integrates geothermal borefields, heat recovery heat pumps, photovoltaic (PV) arrays, and battery storage. Compared to the baseline system – gas heating combined with air-source chillers – the proposed TEN reduces annual imported energy by 74% and peak electricity demand by 45%, achieves a levelized cost of energy of $\$0.210$/kWh, and substantially enhances resilience. Life-cycle costs increase by approximately 6%, and initial investment costs are about 2.5 times higher than the baseline. However, if central plant infrastructure, district loops, and utility-scale PV and battery systems are privately funded and operated, the initial investment would fall below the baseline system cost. Critical to achieving these significant performance improvements were detailed nonlinear dynamic simulations coupling geothermal heat transfer, energy system operation, and realistic feedback control logic. These simulations identified essential design modifications and control strategy refinements that substantially reduced energy use, peak demand, and compressor shortcycling, thereby improving durability and reliability—issues that would have been significantly more expensive to resolve during operation. Additionally, the verification step highlighted sensitivities to key design parameters that could reduce initial investment by approximately $\$2$ million and reduce annual life-cycle costs more than $\$300,000$. We recommend adopting the PBD methodology for future feasibility studies and TEN pilot projects to gain valuable operational experience. Furthermore, we recommend that DoD invest in transferring and scaling the PBD methodology to other installations. This entails developing standardized computational frameworks and component libraries as well as training industry in conducting PBD. Such investments would enable rapid, robust, reliable, and cost-effective retrofits, supporting DoD’s ambitious energy system modernization goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Loop Heat Pipe↗

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Thermal Modeling↗

Experimental Study on Charging and Discharging Performance of a Dual-Purpose Underground Thermal Battery

A dual-purpose underground thermal battery (DPUTB) was proposed for Grid-interactive Efficient Buildings. It integrates underground thermal energy storage with a shallow-buried ground heat exchanger (less than 6 m deep). The charging and discharging performance of a lab-scale DPUTB were experimentally investigated. The test results show that the lab-scale (1:125 in volume) DPUTB can provide 34 W cooling continuously for 3.7 h with a supply water temperature below 14°C. The water temperature rise of the inner tank was slowed down during the discharging process due to the phase change of the phase change material (PCM). Thermal storage capacity was increased by 156% using the PCM that only occupied 19% volume of the inner tank. The heat lost from the inner tank was recovered in the outer tank and led to the efficiency improvement of a ground source heat pump.

Wang, Lingshi↗

Integration of renewable energy generation and storage systems for emissions reduction in an islanded campus microgrid

Microgrid connected building communities are projected to play an integral part in the clean energy transition. These types of systems, when integrated with distributed energy resources (DERs) such as combined heat and power (CHP), district heating and cooling, renewable generation, and energy storage, can provide clean, reliable power to critical facilities and vulnerable communities. The intermittent nature of renewable generation is a challenge when integrating renewables into any grid system, but particularly in islanded microgrids. The University of Texas at Austin (UT) operates an islanded microgrid powered by a CHP plant, while also utilizing district heating and cooling systems and thermal energy storage (TES). High fidelity operating data was used to develop a validated reduced order model of UT’s integrated campus energy systems to serve as a testbed for use in a case study. Hypothetical renewable energy installations on land owned by UT in west Texas were modeled and integrated into the validated campus models along with battery energy storage (BES). Simulations showed that a combination of renewable energy from wind, and optimally controlled 24-hour thermal and battery storage systems could reduce carbon dioxide emissions on campus by 45.4%. The additional retrofit of burner systems to utilize hydrogen natural gas blends resulted in an overall annual emissions reduction of 54.7%. Carbon capture and storage eliminated the majority of the remaining emissions with increased plant energy expenditure. The presented simulations display the practical limitations of a CHP system complemented by renewable generation and short-term storage in eliminating emissions. Furthermore, results highlight the need for further research and development in long duration storage technologies and hydrogen fueled turbines to increase penetration of renewable energy and reduce emissions.

CHP↗

EMU evolution

Evolution of Extravehicular Mobility Unit (EMU) technology is necessary to support the Extravehicular Activity (EVA) requirements of the Space Station Freedom Program and those of the Space Exploration Initiative (SEI). Key qualities supporting long-duration missions include technologies that are highly reliable, durable, minimize logistics requirements, and are in-flight maintainable and serviceable. While these qualities are common to SSF and SEI EVA, development paths will differ where specific mission requirements impose different constraints. Development of reusable, regenerative technologies is necessary to minimize the logistics penalties. Increased battery discharge/recharge cycle life and usable wet life, compact high current density fuel cells, reusable CO2 absorbing media, and thermal radiation coupled with venting heat rejection technologies are just some methods of reducing consumables. Development must strive for durable, reliable systems that are in-flight serviceable and maintainable, which are vital for missions where logistics capabilities are extremely constrained. Key areas include suit components (e.g., gloves, boots, and cooling garments), and life support hardware such as fans, pumps, instrumentation, and emergency O2 systems. Higher pressure suits will reduce EVA prebreathe requirements and pre-EVA operations overall. Many challenges of higher pressure suits have been addressed by on-going development. Emphasis on glove development is necessary to provide low fatigue, dexterous glove mobility at higher suit pressures. Minimum impact hooks and scars which support an advanced SSF EMU have been identified. These accommodations permit upgrades that support servicing of low volume, high pressure oxygen systems, and hydrogen technologies such as fuel cell, and venting hydrogen heat rejection systems.

Rouen, M.↗

Thermal Imaging of Aerospace Battery Cells

Surface Thermal Profiles of Eagle Picher rabbit-ear 50Ah NiH2 and of Saft 40 Ah Li-ion cylindrical cells have been studied using ThermCAM S60 FLIR Systems. Popping Phenomenon in NiH2 cell is demonstrated Temperature gradient in NiH2 is slightly higher than normally considered, for example. Middle of stack to top or bottom is about 12.9 C compared to <7 C (may be due to passive cooling). Less than 1 C thermal gradient on the Li-Ion cell vessel surface. Significantly lower heat generation in Li-Ion cell compared to NiH2 cell. -May be due to a favorable charge method used for Li-Ion cell.

Shue, Jack↗

Assessing fuel cycle design options for advanced microreactors

Microreactor (MR) technology have recently gained traction due to their reduced construction cost compared to traditional large reactors. Their small physical geometry results in increased neutron leakage and deteriorated neutron economy which limits the achievable burnup of MR fuel. Refueling strategy currently discussed in MR design community is the battery-like refueling which is involve replacing the entire reactor core at the end of their operational cycle. Here, this paper investigates partial core refueling as means to increase MR fuel burnup and improve fuel cycle economy as a result. Two fuel cycle design strategies have been successful. These are the partial core refueling and partial core refueling combined with assembly rotation. Both strategies have been tested to operate a heatpipe-cooled MR referred to as the eVinci-like core for 72 Effective Full Power Months (EFPMs). The partial core refueling showed to reduce the refueling requirements by 18% compared to the battery-like refueling strategy. This corresponds to 10.5% reduction in the Net Present Value (NPV) of fuel cost over the 72 EFPMs of operation. The partial core refueling combined with rotation case reduces the refueling requirements by 29% (corresponding to 14.5% reduction in NPV of fuel cost) compared to the battery-like refueling strategy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Unitary Thermal Energy Management for Propulsion Range Augmentation (UTEMPRA) (CRADA Final Report)

NREL will work with Delphi to develop technology that integrates the thermal management of electric drive vehicle sub-systems into a unified thermal system that reduces auxiliary loads and increases vehicle range. The ultimate goal is to create a cost-effective system which improves climate control efficiency through heat pump operation and waste heat recovery, while maintaining occupant thermal comfort and meeting powertrain thermal requirements. The technology will also aim to reduce the number of independent cooling systems required in electric drive vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

Unraveling the formation mechanism of NaCoPO 4 polymorphs

Phosphate compounds are one of the attractive classes of cathodes for their potential application in rechargeable Na-ion batteries (NIBs) due to their high insertion voltages and stabilities. Unlike olivine-LiMPO 4 (M = Fe, Mn, Co, Ni) cathodes, maricite-NaMPO 4 phases are electrochemically inactive due to lack of sodium diffusion channels. Interestingly, cobalt bearing compounds exhibit rich polymorphism (α-, β-, ABW- and Red-NaCoPO 4 ). However, the preparation of NaCoPO 4 single phases is challenging due to their closer enthalpies of formation. In this study, we have attempted to understand the formation mechanism of NaCoPO 4 polymorphs during solid state reaction using two different cobalt precursors (Co(OH) 2 and CoCO 3 ). The temperature dependent in-situ powder X-ray Diffraction (PXRD) studies showed the formation of β-NaCoPO 4 at a much lower temperature compared to the one reported in the literature, whilst we have discovered a new high temperature polymorph gamma-NaCoPO 4 . The choice of precursors was also found to be important for the preparation of ABW-NaCoPO 4 , i.e., the rapid decomposition of Co(OH) 2 has resulted in its formation whilst the high stability of CoCO 3 prohibited the same. The order of the formation of the NaCoPO 4 polymorphs during heating was found to be ABW→β→α →$\gamma$. During normal cooling, gamma-NaCoPO 4 transformed primarily into alpha-polymorph whilst quenching in liquid N-2 resulted in the formation of β-NaCoPO 4 The as-synthesized beta- and ABW-NaCoPO 4 phases exhibited high sodium (de)-intercalation voltages (similar to 4.2 and 4.5 V vs. Na + /Na 0 , respectively), albeit with limited reversible capacities. This study is expected to open new avenues to harvest metastable polymorphs based on other transition metals (Fe, Mn and Ni).

25 ENERGY STORAGE↗

NASA Tech Briefs, August 2009

Topics covered include: Aligning a Receiving Antenna Array to Reduce Interference; Collecting Ground Samples for Balloon-Borne Instruments; Tethered Pyrotechnic Apparatus for Acquiring a Ground Sample; Enhanced Video-Oculography System; Joint Carrier-Phase Synchronization and LDPC Decoding; Dual-Polarization, Sideband-Separating, Balanced Receiver for 1.5 THz Modular Battery Charge Controller; Efficient Multiplexer FPGA Block Structures Based on G4FETs; VLSI Microsystem for Rapid Bioinformatic Pattern Recognition; Low-Noise Amplifier for 100 to 180 GHz; Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures; Inert Welding/Brazing Gas Filters and Dryers; Fabricating Copper Nanotubes by Electrodeposition; Reducing Aerodynamic Drag on Empty Open Cargo Vehicles; Rotary Percussive Auto-Gopher for Deep Drilling and Sampling; More About Reconfigurable Exploratory Robotic Vehicles; Thermostatic Valves Containing Silicone-Oil Actuators; Improving Heat Flux Performance of Flat Surface in Spray-Cooling Systems; Treating Fibrous Insulation to Reduce Thermal Conductivity; Silica-Aerogel Composites Opacified with La(sub0.7)Sr(sub0.3)MnO3; Cyclic Oxidation Behavior of CuCrAl Cold-Sprayed Coatings for Reusable Launch Vehicles; Ceramic Fiber Structures for Cryogenic Load-Bearing Applications; Elastomer Reinforced with Carbon Nanotubes; Biologically Inspired Purification and Dispersion of SWCNTs; A Technique for Adjusting Eigenfrequencies of WGM Resonators; Low-Pressure, Field-Ionizing Mass Spectrometer; Modifying Operating Cycles to Increase Stability in a LITS; Chamber for Simulating Martian and Terrestrial Environments; Algorithm for Detecting a Bright Spot in an Image; Extreme Programming: Maestro Style; Adaptive Behavior for Mobile Robots; Protocol for Communication Networking for Formation Flying; Planning Complex Sequences Using Compressed Representations; and Self-Supervised Learning of Terrain Traversability from Proprioceptive Sensors.

Source record↗

Thermal Storage Performance of a Dual-Purpose Underground Thermal Battery for Shaping the Electric Demand of Buildings

A dual-purpose underground thermal battery (DPUTB) integrates a ground heat exchanger with underground thermal energy storage. It can be installed in shallow boreholes (less than 6 m deep) and thus is less expensive than the conventional ground heat exchangers. The thermal energy storage can be used to shave or shift the electric load for meeting the thermal demands of a building. The charging and discharging performance of a lab-scale DPUTB were tested. The test results show that the DPUTB can be fully charged within 4 h and can provide 34 W cooling continuously for 2.5 h with a supply water temperature below 14°C. A small amount of phase-change material significantly increased the thermal storage capacity.

Wang, Lingshi↗

National Park Service Bus Electrification Study: 2020 Report

This report summarizes important considerations for implementing BEBs in the three national park fleets, detailing information about current buses at each fleet, electric bus demonstration vehicles, as well as performance evaluations of BEBs in Zion, Bryce, and Yosemite. Results include in-use data collection results reporting metrics such as average bus speed, energy usage per trip, and daily distance traveled, as well as effects of high heating, ventilation, and air conditioning (HVAC) system use to both heat and cool the buses, emissions estimations before and after use of electric buses, operating costs, electric vehicle infrastructure, maintenance, and bus driver user experience survey information. Analysis results from this project will help the NPS understand how BEBs and future expansion of BEBs could assist in meeting their bottom line and operational goals and assist NPS in choosing appropriate locations for future BEB deployments.

33 ADVANCED PROPULSION SYSTEMS↗

Methods of making lithium ion conducting sulfide glass

A lithium ion-conductive solid electrolyte including a freestanding inorganic vitreous sheet of sulfide-based lithium ion conducting glass is capable of high performance in a lithium metal battery. Such an electrolyte is also manufacturable, and readily adaptable for battery cell and cell component manufacture, in a cost-effective, scalable manner using an automated machine based system, apparatus and methods based on inline spectrophotometry to assess and inspect the quality of such vitreous solid electrolyte sheets and associated components. Suitable manufacturing methods can involve providing a sulfur precursor, providing a boron precursor material having lithium as a second constituent, combining the sulfur and boron precursor materials to form a precursor mixture, melting the mixture, and cooling the melt to form a solid lithium ion conducting glass. The glass may have a Li+ conductivity of at least 10 −5 S/cm. The boron precursor material may be synthesized by reducing boron oxide to boron metal by heating the boron oxide in direct contact with lithium metal.

Visco, Steven J.↗

Synthesis and post-heating treatment of inorganic NaF·Na 3 SbS 4 solid electrolytes

Sulfide-type sodium (Na) solid electrolytes (SEs) with halide doping have attracted serious interest due to their high ionic conductivity and great potential in solid-state Na batteries. While other halogens such as Cl, Br, I have been studied to enhance Na-ion transport in sulfide-type SEs, the introduction of fluorine (F) is rarely investigated. Moreover, synthetic parameters such as heating treatment temperatures strongly influence the structure and conductive properties of halide-doped sulfide SEs. Herein, we prepared xNaF·(1-x)Na 3 SbS 4 nanocomposites with varying concentration of F using a low-temperature (150 °C) heating method, and studied the effects of post-heating treatment on structure and conductivity. In-situ neutron diffraction was employed to investigate the structural evolution of X-doped Na 3 SbS 4 (X = F, Cl) during the post-heating treatment and cooling process. In addition, the post-heating treatment at 300 °C leads to increased ionic conductivity of xNaF·(1-x)Na 3 SbS 4 nanocomposites with various F contents. After 300 °C post-heating treatment, 0.2NaF·0.8Na 3 SbS 4 exhibited the highest conductivity of 0.48 mS cm –1 at room temperature. Moreover, improved electrochemical stability was also observed in Na-Sn symmetric cells, specially, with prolonged stable cycling for 300 h and much lower polarization voltage (<0.35 V). Furthermore, this work highlights the importance of post-heating treatment on the structural evolution and its role in exploring new halide-incorporated sulfide-type SEs, promoting the development of inorganic solid-state ionic conductors.

25 ENERGY STORAGE↗

Thermal Characterization Study of Lithium-Ion Cells

The primary challenge in designing a full scale lithium-ion (Li-ion) battery system is safety under both normal operating as well as abusive conditions. The normal conditions involve expected charge/discharge cycles and it is known that heat evolves in batteries during those cycles. This is a major concern in the design for high power applications and careful thermal management is necessary to alleviate this concern. An emerging thermal measurement technology, such as the electrochemical calorimetric of batteries, will aid in the development of advanced, safe battery system. To support this technology, several "commercial-off-the-shelf" (COTS) Li-ion cells with different chemistries and designs are being evaluated for different cycling regimes at a given operating temperature. The Accelerated Rate Calorimeter (ARC)-Arbin cycler setup is used to measure the temperature, voltage, and current of the cells at different charge/discharge rates. Initial results demonstrated good cell cyclability. During the cycle testing, the cell exhibited an endothermic cooling in the initial part of the charge cycle. The discharge portion of the cycle is exothermic during the entire discharge period. The presence of an endothermic reaction indicates a significant entropy effect during the beginning of charge cycle. Further studies will be performed to understand the thermal characteristics of the Li-ion cells at the different operating conditions. The effects on the thermal response on cell aging and states-of-charge will also be identified.

Britton, Doris L.↗

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗