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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 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Machine Learning-enabled Scalable Performance Prediction of Scientific Codes

Hardware architectures become increasingly complex as the compute capabilities grow to exascale. Here, we present the Analytical Memory Model with Pipelines (AMMP) of the Performance Prediction Toolkit (PPT). PPT-AMMP takes high-level source code and hardware architecture parameters as input and predicts runtime of that code on the target hardware platform, which is defined in the input parameters. PPT-AMMP transforms the code to an (architecture-independent) intermediate representation, then (i) analyzes the basic block structure of the code, (ii) processes architecture-independent virtual memory access patterns that it uses to build memory reuse distance distribution models for each basic block, and (iii) runs detailed basic-block level simulations to determine hardware pipeline usage. PPT-AMMP uses machine learning and regression techniques to build the prediction models based on small instances of the input code, then integrates into a higher-order discrete-event simulation model of PPT running on Simian PDES engine. We validate PPT-AMMP on four standard computational physics benchmarks and present a use case of hardware parameter sensitivity analysis to identify bottleneck hardware resources on different code inputs. We further extend PPT-AMMP to predict the performance of a scientific application code, namely, the radiation transport mini-app SNAP. To this end, we analyze multi-variate regression models that accurately predict the reuse profiles and the basic block counts. We validate predicted SNAP runtimes against actual measured times.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Minimizing the Electromechanical Stresses in Poloidal Field Coils by Optimizing their Numbers and Locations using FREDA Framework

Poloidal field (PF) and central solenoid (CS) coils play a crucial role in sustaining the equilibrium and preserving the shape of highly confined tokamak plasmas. Ensuring that PF coil current and mechanical stress stay within superconducting and structural limitations is an important check in the design assessment. Minimizing the PF coil currents and mechanical stresses influences reliability, cost, and performance. A free-boundary MHD equilibrium code—FreeGS is employed within the fusion reactor design and assessment (FREDA) whole facility modeling (WFM) framework to construct the plasma equilibrium based on the configuration and currents in the PF coils. Here, we present the capability of the FreeGS code to minimize the currents, forces, and electromagnetic stresses on the PF coils by optimizing their number, sizes, structures, and locations while maintaining an MHD stable plasma configuration with a large confinement factor. The workflow is initialized with a configuration of plasma parameters and coils’ locations from the 0-D tokamak build systems code in the FREDA framework. Then, FreeGS is called to calculate the initial equilibrium at the minimum total current in PF coils. Thereafter, FreeGS’s internal optimizer minimizes the currents and hoop and central forces on the PF coils while maintaining the reference equilibrium. Finally, the input configuration is updated with the optimized parameters for equilibria over the ramp-up phase of a burning-plasma operation. FREDA’s whole facility optimization capability, which includes all magnetic field coil systems, blanket, vacuum vessel (VV), first wall, divertor, etc., is under development and out of the scope for this study.

Hassan, Ehab [ORNL] (ORCID:0000000181060301)↗
DOE OSTI2020

Cost estimates of production scale semitransparent organic photovoltaic modules for building integrated photovoltaics

Building integrated photovoltaics (BIPVs) are attached to commercial and residential structures to enable solar energy harvesting. While conventional Si photovoltaics (PVs) are dominant in the current market, second and third generation thin film solar cells based on amorphous Si, CdTe, CIGS, perovskites or organic photovoltaics (OPVs) are often considered as an alternative for BIPV applications since they may offer reduced costs compared to Si PVs. Indeed, recent advances in performance suggest that lightweight, flexible and visibly transparent OPVs can potentially be integrated into windows or other applications to which Si PVs are less well suited. Here, we estimate the cost of high efficiency, semitransparent OPVs (ST-OPVs) based on solution processing in a roll-to-roll (R2R) manufacturing line. Assuming modules with 10% power conversion efficiency (PCE), a 70% geometric fill factor (GFF), and 95% inverter efficiency, we anticipate a %1.6 per Wp module manufacturing cost that includes the cost of the microinverter to condition the OPV dc output to be compatible with the ac line voltage of the building. The materials and inverter cost comprise ~90% of the total module cost. Hence, with simplified material synthesis and a lower inverter cost, including marginally improved PCE and GFF, we expect the cost can be as low as $0.47 per Wp. Here, while the module costs ~60% of the average (uninstalled) double-pane window, we expect the payback period can be as short as 2 to 6 years, suggesting that OPVs can be an economic and attractive candidate for BIPV applications.

14 SOLAR ENERGY↗
NASA NTRS2024

Bending Performance of Tungsten Printed Via Laser Powder Bed Fusion With Ceramic Dispersion Modified Powder Feedstock

Additively manufactured tungsten is a candidate refractory material for high-temperature aerospace and nuclear fusion/fission applications. The printability of pure tungsten is challenged by cracking defects arising from the metal’s high brittle-to-ductile transition temperature and low solubility of interstitial impurities. Furthermore, the cast microstructure inherent to the laser powder bed fusion (L-PBF) process has limited strength compared to worked microstructures common in wrought tungsten. Aside from process-related techniques to mitigate defects and increase strength (e.g., heated build chambers, multi-laser systems, low oxygen environmental control, etc.), micro-alloying additions can positively influence tungsten printability and strength. In this work, pure tungsten L-PBF feedstock was modified with 1 wt% additions of ceramic compound nano-powders. Wrought and printed bars were evaluated in four-point bending. Flexural strength and fractography were primary means of comparison to assess the effect of the feedstock modification on printed tungsten mechanical performance.

Additive Manufacturing↗
NASA NTRS1997

A Low-Power High-Speed Smart Sensor Design for Space Exploration Missions

A low-power high-speed smart sensor system based on a large format active pixel sensor (APS) integrated with a programmable neural processor for space exploration missions is presented. The concept of building an advanced smart sensing system is demonstrated by a system-level microchip design that is composed with an APS sensor, a programmable neural processor, and an embedded microprocessor in a SOI CMOS technology. This ultra-fast smart sensor system-on-a-chip design mimics what is inherent in biological vision systems. Moreover, it is programmable and capable of performing ultra-fast machine vision processing in all levels such as image acquisition, image fusion, image analysis, scene interpretation, and control functions. The system provides about one tera-operation-per-second computing power which is a two order-of-magnitude increase over that of state-of-the-art microcomputers. Its high performance is due to massively parallel computing structures, high data throughput rates, fast learning capabilities, and advanced VLSI system-on-a-chip implementation.

Fang, Wai-Chi↗
DOE OSTI2022

Hermetically sealed porous-wall hollow microspheres enabled by monolithic glass coatings: Potential for thermal insulation applications

Thermal insulation materials are crucial to improve the energy performance of buildings and industrial applications. We report an approach to create hermetically vacuum-sealed silica-based hollow microspheres that can lower the thermal conductivity of closed-cell insulation materials. The wall structure of these hollow microspheres includes a reticulated network of pores or channels that extend through the thickness of the wall. When a thin layer of glass material is applied to the wall exterior, followed by a vacuum-assisted thermal treatment process, the coated microsphere surfaces display a highly dense conformal coverage and near-complete elimination of surface porosity. The sealing efficiency of these microspheres is verified by trapping argon within their cavities as well as through evacuating their hollow cores. Notably, incorporating the evacuated microspheres into a polymer matrix resulted in ~27% enhancement in its thermal insulation performance and no notable loss of performance was observed following three months of exposure to ambient conditions. Thus, we believe that the present study offers a commercially viable strategy that opens the door to applications of such inorganic hollow particles in areas ranging from vacuum-based thermal insulation systems to catalysis, separation technologies, and medical fields.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Damage Detection and Electrical Performance Impact of Flat-Flexible Circuits

Flat-flexible circuits or ‘flex circuits’ have varied applications in electronics and in explosive detonation systems. They pose advantages over conventional coaxial cables in their ability to fit into small mechanical envelopes and routings. A typical flex circuit is composed of a laminated assembly of multiple layers of conductor and dielectric materials. Copper, because of its high electrical conductivity, is one of the primary materials used in flex circuit conductors. The conductor must maintain structural integrity and electrical continuity when the flexible circuit is bent during processing or to fit an application envelope. Under some strain conditions a cable may have degraded electrical performance even though visible damage may not be evident. Dislocation density can increase by mechanisms such as dislocation forest hardening, where gliding dislocations in primary slip planes get pinned at obstacles and form Frank-Read sources. Dislocation density increases within the conductor layers may impact electrical resistivity but would not necessarily result in visible mechanical failure. In some detonation applications, such as for building implosion for demolition, the time for signal transmission and voltage used for firing detonators can be critical. If the resistance in a single flex cable within a building demolition array is too high, the resultant demolition shape may be asymmetric, leading to unplanned damage to nearby structures and potential hazards to public safety. This study will apply non-destructive evaluation techniques to evaluate the detectability of damage accumulation in flat, flexible copper-conductor cables and discuss potential implications to their practical use.

42 ENGINEERING↗
DOE OSTI2023

Empirical validation of building energy simulation model input parameter for multizone commercial building during the cooling season

This paper presents a critical advancement in Building Energy Modeling (BEM) through an empirical validation approach using a high-quality dataset from a multizone commercial office building in Oak Ridge, TN, USA. BEM is widely utilized in diverse construction applications, but its effectiveness relies on the accuracy of its predictions. The study focuses on empirical validation of input parameters in BEM, including building envelope data, infiltration modeling, and rooftop unit system performance curves. The validation of simulation input parameters leads to substantial improvements in the accuracy of simulation results. Notable both NMBE and cv (RMSE) values are reduced by 0.5 % for indoor air temperature and 17 % for indoor air relative humidity compared to the previous model. At the system level, both NMBE and cv (RMSE) values are reduced by 2 % for fan energy consumption and 4 % for cooling energy consumption, compared to the previous model. A literature review highlights a significant gap in empirical validation studies, which predominantly concentrate on either component-level or whole building validation. Furthermore, many studies employ simplified setups that may not faithfully represent the complexities of multizone commercial buildings. This paper distinguishes itself by emphasizing the critical importance of component-level input parameter validation. It underlines the need to validate data related to building envelope components and HVAC system performance curves, resulting in more accurate simulation outcomes. In conclusion, the utilization of actual multizone commercial building data enhances the study's practical relevance. In summary, this research underscores the pivotal role of input parameter validation in enhancing the accuracy and reliability of BEM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Strong and Efficient Consistency with Consistency-aware Durability

We introduce consistency-aware durability or C ad , a new approach to durability in distributed storage that enables strong consistency while delivering high performance. We demonstrate the efficacy of this approach by designing cross-client monotonic reads , a novel and strong consistency property that provides monotonic reads across failures and sessions in leader-based systems; such a property can be particularly beneficial in geo-distributed and edge-computing scenarios. We build O rca , a modified version of ZooKeeper that implements C ad and cross-client monotonic reads. We experimentally show that O rca provides strong consistency while closely matching the performance of weakly consistent ZooKeeper. Compared to strongly consistent ZooKeeper, O rca provides significantly higher throughput (1.8--3.3×) and notably reduces latency, sometimes by an order of magnitude in geo-distributed settings. We also implement C ad in Redis and show that the performance benefits are similar to that of C ad ’s implementation in ZooKeeper.

Computer Science↗
DOE OSTI2023

Advances in Binder Jet Additive Manufacturing

Binder Jetting is a powerful additive manufacturing technology due to its low cost and wide range of types of materials it can shape. The industry partner ExOne has a range of binder jet products for applications such as casting tools, composite layup tools, single-alloy metal components, and more. As such, research and development is of high interest in the area of specialized binders for each type of material, processing technology that improves reliability and quality, and materials to enhance the performance of the final parts. Thus, this work focuses on developing novel binders for sand tools and metal prints, new capabilities in multi-material printing, and build monitoring and correction. The result of this work includes a novel binder system that makes binder jet sand stronger than concrete while still being water soluble, a casting binder that is environmentally friendly and produces better surface finishes on castings, and a binder for metals that reduces the residual carbon.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ComStock Measure Scenario Documentation: Standard Performance Heat Pump Rooftop Unit With New Windows

Building on a 3-year effort to calibrate and validate the U.S. Department of Energy's ResStock (TM) and ComStock (TM) models, this work produces national datasets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of questions regarding their commercial building stock. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual energy consumption (at subhourly resolution) of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. The goal of this work is to develop energy efficiency and demand flexibility end-use load shapes that cover high-impact, market-ready (or nearly market-ready) measures. "Measures" refers to various "what-if" scenarios that can be applied to buildings. An end-use savings shape is the difference in energy consumption between a baseline building (or collection of buildings) and a building with an energy efficiency or demand flexibility measure applied. It results in a time-series profile broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each time step, as well as annual aggregations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Framework and Tool for Artificial Intelligence & Machine Learning (AI/ML) Enabled Automated Non-Destructive Inspection of Composites Aerostructures Manufacturing

Vehicles and systems in the field of aerospace have two major requirements: a high demand for a large quantity and an expectation to perform for their lifetime with little to no failures. Thus, there is a need for a fast production rate of aerospace products with high quality. Improvements to production rate have many benefits, including a reduction in energy consumption per unit manufactured. This would be from factory energy usage, which is required to build and verify a product. Manufacturing process specifications require inspection of parts to determine if any flaws are present. Depending on factory planning and product quality, especially at higher rates, the evaluation process can pose a production rate bottleneck. This project was comprised of using artificial intelligence and machine learning (AI/ML) methods on inspection evaluations with the objective of reducing the required time to produce an aerospace structure or product and without reducing the final quality.

42 ENGINEERING↗
DOE OSTI2026

Do Flashing and Sealant Materials Need to be Exposed to Extreme Cycling?

In the U.S., over 50% of homes were built before 1980, when minimal building codes existed. The aging of building envelopes can significantly contribute to the air leakage, moisture intrusion, and durability of buildings leading to higher energy demands. Although the durability of building materials and envelope systems has been studied extensively, the durability of specific components like window-wall flashing and sealants remains underexplored. Current standards such as ASTM, NIST, and AAMA primarily focus on durability testing considering the high temperatures only and require sealant testing on anodized aluminum panels, leaving questions about performance in cold or fluctuating temperatures unanswered. Current ASTM and AAMA standards provide guidelines for durability testing but predominantly focus on exposure to higher temperature conditions. It remains unclear how exposure to cold temperatures, or cycles of both hot and cold conditions, affect the durability of these materials. Furthermore, AAMA standards mandate that flashing materials be tested on anodized aluminum panels, which may not reflect real-world applications. Therefore, this initial study aims to explore this concern through testing by constructing two window-wall interface prototypes and applying five different flashing and sealant materials to their joints. These samples were subjected to extreme temperatures, ranging from −34 ℃ (−30 °F) to 50 ℃ (122 °F), over a 28-day period (fourteen cycles of 24 hours), with daily visual inspections to document any signs of deterioration such as wrinkling, distortion, or warping. The study has two main objectives: (1) to determine whether flashing and sealant materials lose their durability and strength when exposed to varying climate conditions, specifically cold climates, and (2) to assess whether the interaction of these materials with different substrates (e.g., lumber, PVC, insulation) affects their durability and strength under varying climate conditions. The findings demonstrate how aging impacts the durability of window-wall systems interfaces, justifying future research that potentially could lead to the development of new testing protocols if significant defects are identified.

Palani, Hevar [ORNL] (ORCID:0000000220211994)↗
NASA NTRS2001

High Power Thruster Based on Inductive Magnetized Plasmoid Acceleration

Regardless of the power source, deep space missions will require both high specific impulse (greater than 500 s) and high thrust power (greater than 100kW). These high Isp thrusters will need to have high electrical efficiency (approx. 90%) and low specific mass (alpha approximately less than 10 kg/kW) as well. Additionally they should have high thrust to allow greater mission flexibility. All these requirements can potentially be achieved with the pulsed formation and acceleration of magnetically self-confined plasmoids commonly referred to as compact toroids (CTs). An electromagnetic plasma thruster based on CT acceleration makes an ideal candidate for a high power, high Isp thruster, since the CT is magnetically isolated from the accelerator so that there is no contact between the propellant and the accelerator. The transfer of momentum to the CT occurs through an electromagnetic interaction with the magnetic field. By maintaining an axial magnetic field gradient across it, the directed velocity of the CT can be increased indefinitely. In previous experiments carried out at the University of Washington, CT's of near milligram mass were accelerated to velocities of 250 km/s in a single pulse. The ejection of the plasmoid by an external axial field also avoids the serious problem of detachment, which would occur in thrusters that employ a magnetic mirror or magnetic nozzle. To employ the CT for propulsion, one must design, construct and test a plasma source that is capable of generating a self-confined plasma inductively, and to do it repeatedly at a sufficiently high rep rate. A repetitively pulsed 100 kW level FRC thruster was built and was operated for short bursts at a 10 kHz rep rate and will be described. Another regime for the FRC thruster however is to produce an FRC in a more conventional manner at high voltage and magnetic field. With the large energy transfer with each pulse, the rep rate for this approach is much lower (approximately 100 Hz). This is the approach that is being evaluated at MSFC in the FAST experiment. The purpose of this experiment is to build an FRC thruster, measure its performance characteristics e.g. specific impulse, thrust, and efficiency. This experiment will also be described as well as various mission scenarios that that are well matched for this type of propulsion.

Slough, John↗
NASA NTRSDate not supplied

Celestial Mapping System

Celestial Mapping System (CMS) is a software platform developed by Dr. Agrawal’s team to generate virtual 3D globes for celestial bodies. Various layers are built on top of the virtual globe to provide visualization for high-resolution imagery, enable precise measurements, build analytical capabilities and broad range of functionalities to assist planetary scientists and mission planners. In her June 14th presentation, Dr. Agrawal will showcase the user interactive software platform to virtually travel the lunar terrain, place rovers and instruments on the surface of the moon and perform measurements of various geological features including permanently shadowed regions. Her team’s future goals include building interactive 3D globes for other planetary bodies such as Venus, Mars, and Titan in the solar system.

GIS system↗
DOE OSTI2022

Modeling and Simulation of Air-Source CO2 Heat Pump Water Heater

Carbon dioxide (CO2) has been widely used as working fluid for the vapor-compression refrigeration systems in large marine device. Due to the potential energy efficiency and the favorable environmental properties of CO2 as a working fluid, CO2 heat pump water heater (HPWH) systems are regarded a promising technology for centralized domestic hot water (DHW) heating in residential and commercial buildings. However, there is still at the early stage of appropriately optimizing and improving the energy performance of CO2 HPWH. This requires CO2 HPWH simulation tools capable of capturing the accurate impact of the emerging compressor, throttle device, and heat exchanger technology on CO2 heat transfer and energy efficiency. In this study, high efficiency components (compressors, pumps, fans, heat exchangers) were identified and applied to the state-of-art CO2 HPWH designs and analyzed their performance by using numerical simulation. This was done by simulating the performance of CO2 HPWH using ACMODEL design model combined with the component models developed at Oak Ridge National Laboratory (ORNL) for orifice tube, map-based compressor, and tube-in-tube gas cooler. ACMODEL is an equipment design model for CO2-based air conditioners and heat pumps developed by Purdue University to account for the details of each component. The simulated CO2 HPWH performance was then compared with the heat pump water heater using conventional refrigerants.

Gao, Zhiming↗
NASA NTRS2021

Compass Final Report: Nuclear Electric Propulsion (NEP)-Chemical Vehicle 1.2

Many previous studies have examined sending crews to and from Mars. The most economical involved a ‘conjunction’ class whereby the crew spends around 500 days on Mars waiting for a ‘cheap’ return. The total mission time results in over a 1000-day mission duration (about 3 years). Given the current experience level of only one year on the International Space Station (ISS), it of interest to reduce that time to only two years, thus reducing risk and minimizing required Mars surface infrastructure. The Phase 1.1 Study goal was stated as follows, “Determine the feasibility of a two-year roundtrip class Mars mission concept of operation that enables boots on Mars no later than 2036.” While the Phase1 study did show feasibility for the NEP-Chemical option, the 2036 Opposition opportunity was found to stress the schedule due to proposed technology development schedules. A 2039 Opposition (which requires even more energy than the 2036 case) was chosen as representative for Phase 1.2. Phase 1.2 also sought to further refine the concept, building on the feasibility, but addressing several challenges brought by the red team and habitat team. Given the date of 2039, nearer term technologies, primarily nuclear thermal and nuclear electric were deemed as the most viable for these missions. As will be shown, the energy required to perform such a mission in only two years (for the 2039 opportunity at least) is about three times that of the three-year conjunction mission. The rocket equation shows that this mission would then require several times the propellant of the three-year mission unless the specific impulse (ISP) of the propulsion system can be increased. Based on lunar needs, a limit of five Space Launch System (SLS) launchers with 8.4m fairings was imposed for the piloted transportation portion of the mission, limiting the size of the system. When using nuclear electric propulsion, the main limiting factor was packaging the required radiator area. The higher Isp nuclear electric propulsion (NEP) system option is described herein but with a twist: in order to keep the size of radiators packageable in one SLS and use proven reactor power system technology (~1200K reactor outlet temperature and superalloy-class Brayton) the NEP system had to be combined with a chemical propulsion system. This combination of electric propulsion and high thrust chemical was found to be useful in previous design studies combining solar electric propulsion (SEP) and chemical propulsion. Such a combination allowed the low-thrust system to provide significant change in velocity (∆V) during the interplanetary portions of the mission, thereby notably reducing the ∆V required by the high thrust system to capture and depart from the Mars gravity well. Here the high thrust ‘impulsive’ system is more efficient due to the Oberth Effect. A plethora of trades, both at the mission and system level, as well as the subsystem level were performed to develop these vehicle concepts. An entire family of NEP-Chemical transportation vehicles is described herein. The main driver and the primary focus was the piloted vehicle but additional concepts for cargo were performed using the same ‘building blocks’ in order to reduce costs and provide commonality.

Nuclear Power↗
DOE OSTI2023

Mechanical Properties of Additively Manufactured 316L Stainless Steel Before and After Neutron Irradiation–FY23

This report presents the observed mechanical behavior of the additively manufactured (AM) 316L stainless steel (SS) before and after neutron irradiation. In the Advanced Materials and Manufacturing Technologies (AMMT) program, a variety of mechanical and physical property data are generated and accumulated to assess the AM austenitic alloy for nuclear reactor applications. The testing and evaluation task in the FY 2023 focused on elucidating the effects of sampling location and build size on the mechanical properties of AM 316L SS (in stress-relieved condition) before and after neutron irradiation. The laser powder bed fusion (LPBF) process produced 316L plates of three distinct sizes from which SS-J3 miniature tensile specimens were machined from six different locations. The tensile specimens were irradiated in the High Flux Isotope Reactor (HFIR) normally to 2 and 10 dpa at the target temperatures of 300 °C and 600 °C. Post-irradiation tensile testing was performed at room temperature, 300 °C, and 600 °C. The mechanical properties of AM 316L SS were significantly influenced by the characteristic microstructures of printed materials, which include fine grains and high-density dislocations. Compared with the traditional 316L SS, AM 316L showed higher initial strength and lower ductility. Regardless of sampling location, the AM 316L steel retained relatively high strength and ductility to the highest irradiation dose. A prompt necking at yield (with little uniform ductility) was observed after irradiation at 300 °C but no embrittlement was observed up to 10 dpa. Ductilization by irradiation–the radiation-induced increase of ductility–was observed for the 600 °C irradiation only and it occurred in low dose range only. The neutron irradiation increased the data variation in many tensile property datasets, particularly after 600 °C irradiation, and no clear dependence of tensile properties on build thickness or sampling location was observed.

36 MATERIALS SCIENCE↗