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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Complete Optimization of LPBF Ni-Based Alloys Down-Selected from FY23 Candidate Materials Including, Thermodynamic Modeling, Sample Fabrication and Microstructure Characterization

The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the incorporation of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. In the first category, alloy 718 was studied in 2023, and creep testing at 600°C and 650°C revealed that the alloy exhibited great creep strength after the appropriate annealing but had low ductility. Advanced characterization was recently conducted to highlight the presence of strengthening γ' and γ" precipitates after creep testing and to show that brittle phases at grain boundaries might explain the low ductility of LPBF 718 compared with wrought 718. For the high-temperature, high-strength alloys, previously purchased powders of alloys 617, 230, and 625 were used to assess the printability of these three solution-strengthened alloys. Hot cracking could not be suppressed for alloy 617 and 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looked like a promising candidate for various reactor technologies. The fabrication of alloy 282 by LPBF, a γ'-strengthened alloy with great creep strength up to 800°C, was performed in 2023, and x-ray computed tomography (XCT) scans of the alloy before and after creep testing at 750°C were carried out to assess the effect of flaws on the alloy’s creep behavior. Correlation between the flaws’ volume fraction, creep ductility, and creep lifetime could be established, and future work on LPBF 625 will take full advantage of in situ printing data and ex situ XCT scans to accelerate the alloy qualification. Finally, single track experiments were performed on the two alloys previously identified as good molten salt–resistant, Ni-based candidates: Hastelloy N and 244. Various laser parameters were considered, and cracking was not observed for either of the two alloys. Wrought 244 offers better creep strength and molten salt compatibility than alloy 625, and future work will aim to establish the alloy LPBF processing window.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Earth Science Technology Office (ESTO) New Observing Strategies (NOS) and NOS-Testbed (NOS-T)

With the advancement of space hardware technologies such as smaller spacecraft, component and instrument miniaturization and high performance space processors, and with the advancement of software technologies in artificial intelligence, big data analysis and autonomous decision making, Earth Science is looking at novel ways to observe phenomena that previously could not have been studied or would have been too expensive to study with traditional missions. In particular, the New Observing Strategies (NOS) component of the NASA Earth Science Technology Office (ESTO) Advanced Information Systems Technology (AIST) Program aims at leveraging these novel technologies as well as low cost and easy access to space to acquire multi-temporal or simultaneous multi-angular, multi-locations, multi-resolution and multi-spectral observations that will provide better multi-source measurements and will build a more dynamic and comprehensive picture of Earth Science phenomena that need to be studied and analyzed. For applications such as water resources management, air quality monitoring, biodiversity studies or disaster management, NOS will integrate the use of small instruments, small spacecraft, constellations of spacecraft and networks of sensors to design new missions that will provide the necessary measurements to improve future forecast and science modeling systems.Measurement acquisition will therefore be approached as a system of systems rather than on a mission basis, and a system of this complexity should not be expected to work without full integration and experimental characterization. Although most of the individual technologies enabling to link and coordinate multi-source observations are more or less mature, a few technologies need to be developed and all of them need to be integrated and tested as a system. In order for this validation to occur, the AIST Program is developing the NOS Testbed that includes 3 main goals:1.Validate novel NOS technologies, independently and as a system2.Demonstrate novel distributed operations concepts3.Socialize new Distributed Spacecraft Mission (DSM) and SensorWeb (SW) technologies and concepts to the science community by significantly retiring the risk of integrating these new technologies.The NOS Testbed will consist of multiple sensing nodes, simulated or actual, representing space, air and/or ground measurements, that are interconnected by a communications fabric (infrastructure that permits nodes to transmit and receive data between one another and interact with each other). Each node will be supported by hardware capabilities required to perform nodes monitoring and command & control, as well as intelligent "onboard" computing. The nodes will work together in a collaborative manner to demonstrate optimal science capabilities. The testbed will enable to validate technologies such as inter-node communication models, techniques and protocols; inter-node coordination; real-time data fusion and understanding; planning; sensor re-targeting; etc. Additionally, the testbed will have the capability to interact with various mission design tools, OSSEs and one or several forecast models. More details about the NOS Testbed will be presented at the confererence.

Earth Science missions; Advanced information Syste↗
NASA NTRS2013

Process Optimization of Bismaleimide (BMI) Resin Infused Carbon Fiber Composite

Engineers today are presented with the opportunity to design and build the next generation of space vehicles out of the lightest, strongest, and most durable materials available. Composites offer excellent structural characteristics and outstanding reliability in many forms that will be utilized in future aerospace applications including the Commercial Crew and Cargo Program and the Orion space capsule. NASA's Composites for Exploration (CoEx) project researches the various methods of manufacturing composite materials of different fiber characteristics while using proven infusion methods of different resin compositions. Development and testing on these different material combinations will provide engineers the opportunity to produce optimal material compounds for multidisciplinary applications. Through the CoEx project, engineers pursue the opportunity to research and develop repair patch procedures for damaged spacecraft. Working in conjunction with Raptor Resins Inc., NASA engineers are utilizing high flow liquid infusion molding practices to manufacture high-temperature composite parts comprised of intermediate modulus 7 (IM7) carbon fiber material. IM7 is a continuous, high-tensile strength composite with outstanding structural qualities such as high shear strength, tensile strength and modulus as well as excellent corrosion, creep, and fatigue resistance. IM7 carbon fiber, combined with existing thermoset and thermoplastic resin systems, can provide improvements in material strength reinforcement and deformation-resistant properties for high-temperature applications. Void analysis of the different layups of the IM7 material discovered the largest total void composition within the [ +45 , 90 , 90 , -45 ] composite panel. Tensile and compressional testing proved the highest mechanical strength was found in the [0 4] layup. This paper further investigates the infusion procedure of a low-cost/high-performance BMI resin into an IM7 carbon fiber material and the optical, chemical, and mechanical analyses performed.

Ehrlich, Joshua W.↗
NASA NTRS2014

Range-Specific High-Resolution Mesoscale Model Setup: Data Assimilation

Mesoscale weather conditions can have an adverse effect on space launch, landing, and ground processing at the Eastern Range (ER) in Florida and Wallops Flight Facility (WFF) in Virginia. During summer, land-sea interactions across Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS) lead to sea breeze front formation, which can spawn deep convection that can hinder operations and endanger personnel and resources. Many other weak locally driven low-level boundaries and their interactions with the sea breeze front and each other can also initiate deep convection in the KSC/CCAFS area. Some of these other boundaries include the Indian River breeze front, Banana River breeze front, outflows from previous convection, horizontal convective rolls, convergence lines from other inland bodies of water such as Lake Okeechobee, the trailing convergence line from convergence of sea breeze fronts due to the shape of Cape Canaveral, frictional convergence lines from the islands in the Bahamas, convergence lines from soil moisture differences, convergence lines from cloud shading, and others. All these subtle weak boundary interactions often make forecasting of operationally important weather very difficult at KSC/CCAFS during the convective season (May-Oct). These convective processes often build quickly, last a short time (60 minutes or less), and occur over small distances, all of which also poses a significant challenge to the local forecasters who are responsible for issuing weather advisories, watches, and warnings. Surface winds during the transition seasons of spring and fall pose the most difficulties for the forecasters at WFF. They also encounter problems forecasting convective activity and temperature during those seasons. Therefore, accurate mesoscale model forecasts are needed to aid in their decision making. Both the ER and WFF would benefit greatly from high-resolution mesoscale model output to better forecast a variety of unique weather phenomena. Global and national scale models cannot properly resolve important local-scale weather features at each location due to their horizontal resolutions being much too coarse. Therefore, a properly tuned model at a high resolution is needed to provide improved capability. This task is a multi-year effort in which the Applied Meteorology Unit (AMU) will tune the Weather Research and Forecasting (WRF) model individually for each range. The goal of the first year, the results of which are in this report, was to tune the WRF model based on the best model resolution and run time while using reasonable computing capabilities. To accomplish this, the ER and WFF supported the tasking of the AMU to perform a number of sensitivity tests in order to determine the best model configuration for operational use at each of the ranges to best predict winds, precipitation, and temperature (Watson 2013). This task is a continuation of that work and will provide a recommended local data assimilation (DA) and numerical forecast model design optimized for the ER and WFF to support space launch activities. The model will be optimized for local weather challenges at both ranges.

Global and national scale models↗
NASA NTRS2016

A Fly-Through Mission Strategy Targeting Peptide as a Signature of Chemical Evolution and Possible Life in Enceladus Plumes

In situ detection of organic molecules in the extraterrestrial environment provides a key step towards better understanding the variety and the distribution of building blocks of life and it may ultimately lead to finding extraterrestrial life within the Solar System. Here we present combined results of two separate experiments that enable us to realize such in situ life signature detection from the deep habitats of the "Ocean World": a hydrothermal reactor experiment simulating complex organic synthesis and a simulated fly-through capture experiment of organic-bearing microparticles using silica aerogels, followed by subsequent analysis. Both experiments employ peptide as a plausible organics existing in Encleadus plume particles produced in its subsurface ocean. Recent laboratory hydrothermal experiments and a theoretical model on silica saturation indicated an on going hydrothermal reactions in subsurface Enceladus ocean. Given the porous chondritic origin of the core, it is likely that organic compounds originated by radiation chemistry such as amino acid precursors could have been provided, leached, and altered through widespread water-rock interactions. By using the same laboratory experimental setup from the latest water-rock interaction study, we performed amino acid polymerization experiments for 144 days and monitored the organic complexity changing over time. So far over 3,000 peaks up to the size of greater than 600 MW were observed through the analysis of capillary electrophoresis time-of-flight mass spectrometry (CE-TOF-MS) with an indication of amino acid derivatives and short peptides. Generally abiotic polymerization of enantiomeric amino acids results in forming stereoisomeric peptides with identical molecular weight and formula as opposed to homochiral biopolymers. Assuming Enceladus plume particles may contain a mixture of stereoisomeric peptides, we were able to distinguish 16 of the 17 stereoisomeric tripeptides as a test sample using capillary electrophoresis (CE) under optimized conditions. We further conducted Enceladus plume fly-through capture experiment by accelerating peptides soaked in rock particles up to a speed of 5.7 km/s and capturing with originally developed hydrophobic silica aerogels. Direct peptide extraction with acetonitrile-water followed by CE analysis led to detection of only but two stereoisomeric acidic peptide peaks, presenting the first run-through hypervelocuty impact sample analysis targeting peptides as key molecule to to understand the ongoing astrobiology on Enceladus.

organic molecules↗
DOE OSTI2023

Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (DEMO-FTES) [Abstract]

Approximately half of global energy consumption is used for heating and cooling. Because fossil fuels are used to meet most of this demand, heating and cooling of buildings produces a large portion of global greenhouse gas (GHG) emissions. The proposed project seeks to demonstrate the feasibility of a seasonal thermal energy storage concept called fracture thermal energy storage (FTES), which has the potential to dramatically lower energy requirements for heating and cooling and improve the resilience of building energy systems. FTES is a technique for building a highly efficient heat exchanger by creating a carefully designed set of fractures in the ground below a building. This heat exchanger allows thermal energy to be stored over seasonal timeframes—for example, hot thermal energy that is easily captured in the summer or energy from waste heat sources—to meet heating needs during colder months. FTES offers a solution with a relatively small footprint and lower cost compared to currently operating aquifer thermal energy storage (ATES) systems and could be used in the many areas without aquifers suitable for ATES. If commercialized, FTES systems could exceed the 2.5 TWh of energy storage per year from the more than 2,800 ATES systems in operation worldwide, which range from 0.1 MW to 30 MW. The savings in CO2 emissions per year are also expected to match or exceed individual ATES projects, with the largest, a 30 MW system used to provide heating and cooling to the University of Technology in Eindhoven in the Netherlands, estimated to save 13,000 tons of CO2 emissions per year. FTES utilizes mature drilling and fracturing technology and therefore has the potential to be rapidly commercialized once demonstrated. The ability to construct and establish flow through an FTES heat exchanger has been demonstrated by a previous project and the potential for efficient, large-capacity energy storage has been shown using numerical models. However, no experimental validation of these numerical estimates of thermal energy storage has been made. The first crucial need to advance FTES technology is to identify the sensitivity of key metrics such as thermal energy storage and production rates, capacities, and efficiencies to design parameters such as the number of fractures, depth/temperature of fractures, size of fractures, and circulation rates. The second crucial need is experimental testing of achievable thermal performance with optimized system design parameters. The proposed scope of work seeks to systematically address these two critical needs through a highly complementary international collaboration spanning theory, laboratory, and mesoscale field evaluation. The proposed work plan calls for using dimensional analysis and existing state-of-the-art numerical simulators to design carefully scaled laboratory and 10-meter-scale field tests of the thermal efficiency of FTES. The existing advanced laboratory and intermediate-scale field testbeds that will be used for this project will allow for detailed monitoring of the system performance during the test and of how the performance changes across time and length scales. These results will determine the feasibility of full- scale FTES systems. If the thermal performance is consistent with model predictions, the results will provide a strong economic justification for rapid commercialization of FTES technology in a wide range of geographical areas.

25 ENERGY STORAGE↗
NASA NTRS2011

Large Aperture "Photon Bucket" Optical Receiver Performance in High Background Environments

The potential development of large aperture groundbased "photon bucket" optical receivers for deep space communications, with acceptable performance even when pointing close to the sun, is receiving considerable attention. Sunlight scattered by the atmosphere becomes significant at micron wavelengths when pointing to a few degrees from the sun, even with the narrowest bandwidth optical filters. In addition, high quality optical apertures in the 10-30 meter range are costly and difficult to build with accurate surfaces to ensure narrow fields-of-view (FOV). One approach currently under consideration is to polish the aluminum reflector panels of large 34-meter microwave antennas to high reflectance, and accept the relatively large FOV generated by state-of-the-art polished aluminum panels with rms surface accuracies on the order of a few microns, corresponding to several-hundred micro-radian FOV, hence generating centimeter-diameter focused spots at the Cassegrain focus of 34-meter antennas. Assuming pulse-position modulation (PPM) and Poisson-distributed photon-counting detection, a "polished panel" photon-bucket receiver with large FOV will collect hundreds of background photons per PPM slot, along with comparable signal photons due to its large aperture. It is demonstrated that communications performance in terms of PPM symbol-error probability in high-background high-signal environments depends more strongly on signal than on background photons, implying that large increases in background energy can be compensated by a disproportionally small increase in signal energy. This surprising result suggests that large optical apertures with relatively poor surface quality may nevertheless provide acceptable performance for deep-space optical communications, potentially enabling the construction of cost-effective hybrid RF/optical receivers in the future.

photon bucket detection↗
DOE OSTI2024

Differentiable Multiphysics Codes: A Breakthrough Technology for Simulation and Computing

This document summarizes the findings of a strategic planning exercise commissioned by the Weapons Simulation and Computing, Computational Physics (WSC/CP) program at the Lawrence Livermore National Laboratory (LLNL) in FY24. During the year, the committee met with multiple stakeholder communities to gather input, opinions, suggestions and concerns which have been incorporated throughout this document. The key findings from this exercise are summarized: • The development of multiphysics modelling and simulation (mod/sim) codes and software technologies, their deployment on exascale compute platforms, and their broad adoption across the NNSA is a major success of the Advanced Simulation and Computing (ASC) program and the Exascale Computing Project (ECP). Sustained investment in these core technologies is essential. • Today’s state of the art involves running ensembles of O(100K) simulations to perform uncertainty quantification (UQ) and design studies using multiple statistical methods such as Bayesian optimization to understand sensitivities of our models and explore parameterized design spaces. Even with exascale computing, we are practically limited to O(10) parameters in these studies since the number of simulations required to sample the space scales exponentially with the number of design parameters. • The data from these simulation ensembles is increasingly being used to train machine learned (ML) surrogates (or reduced order models, ROMs) which can then be used for optimization or real time design exploration. However, the trained surrogates are still limited in the number of parameters they can represent due to the sampling limitations previously noted. • Augmenting our suite of integrated multiphysics simulation codes, both current and emerging, with the ability to compute gradients (solution derivatives) of arbitrary simulation outputs with respect to (some or all) simulation inputs would be a breakthrough technology, opening the door to a new era of efficient and automated inverse design based on verified and validated mod/sim capabilities. • This capability, which we refer to as differentiable multiphysics codes (DMCs), would revolutionize both UQ and optimization studies by breaking the curse of dimensionality that presently limits our “gradient-free” ensemble based computing approach. A similar breakthrough occurred in the AI/ML community once the ability to compute gradients of arbitrary loss functions using back-propagation became commonplace. Gradient information from the multiphysics codes can also be used to dramatically improve the efficiency and scale of training of ML/ROM surrogates for rapid assessments. • Achieving this in our suite of codes will be a grand challenge, similar to the amount of effort that was required to transition from CPU to GPU computing. It will require buy-in from the entire WSC/CP program and beyond, including all integrated codes, physics and engineering models, third-party library dependencies and performance portability abstractions. It will also require investment in research and development of numerical methods for computing adjoints of coupled physics across multiple adaptively refined moving meshes and of stochastic (Monte Carlo) and mesh free (SPH) methods. • New software and numerical techniques, largely pioneered by the AI/ML community, make this feasible. Chief among these is automatic differentiation (AD), the ability to employ AD at point-wise locations in a physics calculation (instead of traditional black-box approaches) and the ability to perform “back-propagation in time” (or reverse mode AD) for non-linear partial differential equations (PDEs). Fundamentally, the conclusion of this strategic planning exercise is that the time is right to undertake a large scale effort in WSC, centered on the existing integrated codes, to continue the natural evolution of mod/sim in the age of AI/ML. Instead of attempting to replace mod/sim with purely data driven AI/ML models, we believe the key to success is to integrate AI/ML by building on top of the decades of hard-won knowledge and the verified/validated multiphysics modelling capability that is the hallmark of the ASC program.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Solving high-dimensional partial integral differential equations: The finite expression method

Partial integro-differential equations (PIDEs) have broad applications in the sciences, from electro-magnetism to options pricing. Here, in this paper, we introduce a new finite expression method (FEX) to solve PIDEs. This approach builds upon the original FEX and its inherent advantages with new advances: 1) A novel method of parameter grouping is proposed to reduce the number of coefficients in high-dimensional function approximation; 2) A Taylor series approximation method is implemented to significantly improve the computational efficiency and accuracy of the evaluation of the integral terms of PIDEs. The new FEX based method, denoted FEX-PG to indicate the addition of the parameter grouping (PG) step to the algorithm, provides both high accuracy and interpretable numerical solutions, with the outcome being an explicit equation that facilitates intuitive understanding of the underlying solution structures. These features are often absent in traditional methods, such as finite element methods (FEM) and finite difference methods, as well as in deep learning-based approaches. To benchmark our method against recent advances, we apply the new FEX-PG to solve benchmark PIDEs in the literature. In high-dimensional settings, FEX-PG exhibits strong and robust performance, achieving relative errors on the order of single precision machine epsilon, significantly outperforming existing approaches based on neural networks.

Combinatorial optimization↗
DOE OSTI2025

Optimizing Alabama’s CO 2 Storage in Shelby County (Project OASIS) - Deliverable Task 7: Risk Assessment

The “Optimizing Alabama’s CO 2 Storage in Shelby County: Project OASIS” CarbonSAFE Phase II Project seeks to build on regional data sets that demonstrate that the subsurface within Shelby County, Alabama has the potential to store commercial volumes of CO 2 safely, permanently, and economically. The primary target CO 2 Storage Complex is the deep Ketona Dolomite located within a 140 square mile area of the Valley and Ridge Region of Alabama. This deep saline reservoir is beneath a confining system encompassing at least 6,500 ft of shales and other low permeability sediments. Project OASIS drilled a deep stratigraphic test well to confirm the geological properties of the confining system and storage reservoir(s) within the Storage Complex. The geological data was incorporated into numerical models to establish the areal extent of the CO 2 plume and help design the storage site and its monitoring system. The project is managed by the Southern States Energy Board (SSEB), an interstate compact organization consisting of governors and state legislative leaders from sixteen southern states, Puerto Rico, and the U.S. Virgin Islands, as well as an appointee by the President of the United States. The organizational compact provides it with access to state government organizations and legislatures. The Board also maintains an Associate Members program comprised of energy resource companies, utilities, trade groups, academic R&D science and technology experts and energy consultants. Further, the SSEB staff is experienced in managing and coordinating complex energy and environmental programs, from research programs to full-scale design and demonstrations of new and innovative technologies. Project OASIS is a public-private partnership of six entities with multiple principal investigators (PIs). SSEB’s Lead PI and Co-PI are responsible for all aspects of project performance in accordance with the DOE-NETL Cooperative Agreement. SSEB has issued subgrants to Advanced Resources International, Inc., Alabama A&M University, Auburn University, Crescent Resource Innovation, and Oklahoma State University. Advanced Resources International, Inc., issued subgrants to Baker Hughes and Loudon Technical Services for field services

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1985

Advanced Gas Turbine (AGT) technology report

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and producibility experiments at Pontiac comprised AGT 100 activities of this period, January to December 1984. Two experimental engines were available and allowed the evaluation of eight experimental assemblies. Operating time accumulated was 115 hr of burning and 156 hr total. Total cumulative engine operating time is now 225 hr. Build number 11 and 12 of engine S/N 1 totaled 28 burning hours and constituted a single assembly of the engine core--the compressor, both turbines, and the gearbox. Build number 11 of engine S/N 1 included a 1:07 hr continuous test at 100% gasifier speed (86,000 rpm). Build number 8 of engine S/N 2 was the first engine test with a ceramic turbine rotor. A mechanical loss test of an engine assembly revealed the actual losses to be near the original design allowance. Component development activity included rig testing of the compressor, combustor, and regenerator. Compressor testing was initiated on a rig modified to control the transfer of heat between flow path, lubricating oil, and structure. Results show successful thermal decoupling of the rig and lubricating/cooling oil. Rig evaluation of a reduced-friction compressor was initiated. Combustor testing covered qualification of ceramic parts for engine use, mapping of operating range limits, and evaluation of a relocated igniter plug. Several seal refinements were tested on the hot regenerator rig. An alternate regenerator disk, extruded MAS, was examined and found to be currently inadequate for the AGT 100 application. Also, a new technique for measuring leakage was explored on the regenerator rig. Ceramic component activity has focused on the development of state-of-the-art material strength characteristics in full-scale hardware. Injection-molded sintered alpha-SiC rotors were produced at Carborundum in an extensive process and tool optimization study.

Source record↗
DOE OSTI2020

Performance of an Isobaric Hybrid Compressed Air Energy Storage System at Minimum Entropy Generation

Efficient, large-scale, and cost-effective energy storage systems provide a means of managing the inherent intermittency of renewable energy sources and drastically increasing their utilization. Compressed air energy storage (CAES) and its derivative architectures have received much attention as a viable solution; however, optimization objectives for these systems have not been thoroughly investigated in the literature. In this work, a hybrid thermal and compressed air energy storage (HT-CAES) system is investigated that mitigates the shortcomings of the otherwise attractive conventional CAES systems and its derivatives—shortcomings such as strict geological locations, low energy densities, and the production of greenhouse gas emissions. The HT-CAES system allows a portion of the available energy to operate a compressor and the remainder to be converted and stored in the form of heat through joule/resistive heating in a high-temperature, sensible, thermal energy storage medium. Internally reversible and irreversible HT-CAES system assumptions were investigated, in addition to regenerative and non-regenerative design configurations. Several system optimization criteria were examined—including maximum energy efficiency, maximum exergy efficiency, maximum work output, and minimum entropy generation—with a focus on whether the latter may lead to conclusive design guidelines in a real system. It is shown that an HT-CAES system designed based on a minimum entropy generation objective may operate at a lower energy and exergy efficiency as well as lower output power than otherwise achievable. Furthermore, optimization objective equivalence is shown to be limited to certain design conditions.

25 ENERGY STORAGE↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Optimizing Cornell’s future geothermal district heating performance through systems engineering and simulation

Cornell University’s intention to lower its carbon footprint has motivated this engineering evaluation of using low-temperature geothermal energy to supply heat to the campus district energy system. Optimal selection and operation of heat pumps can significantly improve system performance. To support this analysis, we model the quantitative relationships between heat pump configurations and source flow, supply and distribution temperatures, facility heating design options, output heat generation, and carbon abatement outcomes. A systems approach is used for analysis, troubleshooting, and improvement of the model. The result of this effort is a dynamic tool that appropriately responds to hourly thermal demand and communicates energy response for techno-economic analysis. Simulations indicate that a single well-pair in the local Basement Contact Zone reservoir can satisfy almost 68% of annual thermal demand at nearly 20 MWth average capacity while remaining financially competitive compared to conventional heating with levelized cost of heating (LCOH) as low as $4.55/MMBTU ($15.53/MWh th ). A direct-use scheme with heat pump augmentation provided more carbon abatement and 50 to 150% more annual heat supply than one without augmentation. Exploration of three and four well-pair scenarios prove the capability to achieve 50 MW th baseload heating capacity with competitive LCOH and significant carbon reductions.

15 GEOTHERMAL ENERGY↗
NASA NTRS2002

Maximizing TDRS Command Load Lifetime

The GNC software onboard ISS utilizes TORS command loads, and a simplistic model of TORS orbital motion to generate onboard TORS state vectors. Each TORS command load contains five "invariant" orbital elements which serve as inputs to the onboard propagation algorithm. These elements include semi-major axis, inclination, time of last ascending node crossing, right ascension of ascending node, and mean motion. Running parallel to the onboard software is the TORS Command Builder Tool application, located in the JSC Mission Control Center. The TORS Command Builder Tool is responsible for building the TORS command loads using a ground TORS state vector, mirroring the onboard propagation algorithm, and assessing the fidelity of current TORS command loads onboard ISS. The tool works by extracting a ground state vector at a given time from a current TORS ephemeris, and then calculating the corresponding "onboard" TORS state vector at the same time using the current onboard TORS command load. The tool then performs a comparison between these two vectors and displays the relative differences in the command builder tool GUI. If the RSS position difference between these two vectors exceeds the tolerable lim its, a new command load is built using the ground state vector and uplinked to ISS. A command load's lifetime is therefore defined as the time from when a command load is built to the time the RSS position difference exceeds the tolerable limit. From the outset of TORS command load operations (STS-98), command load lifetime was limited to approximately one week due to the simplicity of both the onboard propagation algorithm, and the algorithm used by the command builder tool to generate the invariant orbital elements. It was soon desired to extend command load lifetime in order to minimize potential risk due to frequent ISS commanding. Initial studies indicated that command load lifetime was most sensitive to changes in mean motion. Finding a suitable value for mean motion was therefore the key to achieving this goal. This goal was eventually realized through development of an Excel spreadsheet tool called EMMIE (Excel Mean Motion Interactive Estimation). EMMIE utilizes ground ephemeris nodal data to perform a least-squares fit to inferred mean anomaly as a function of time, thus generating an initial estimate for mean motion. This mean motion in turn drives a plot of estimated downtrack position difference versus time. The user can then manually iterate the mean motion, and determine an optimal value that will maximize command load lifetime. Once this optimal value is determined, the mean motion initially calculated by the command builder tool is overwritten with the new optimal value, and the command load is built for uplink to ISS. EMMIE also provides the capability for command load lifetime to be tracked through multiple TORS ephemeris updates. Using EMMIE, TORS command load lifetimes of approximately 30 days have been achieved.

Brown, Aaron J.↗
NASA NTRS2015

Evolving Design Criteria for Very Large Aperture Space Based Telescopes and Their Influence on the Need for Integrated Tools in the Optimization Process

NASA's Advanced Mirror Technology Development (AMTD) program has been developing the means to design and build the future generations of space based telescopes. With the nearing completion of the James Webb Space Telescope (JWST), the astrophysics community is already starting to define the requirements for follow-on observatories. The restrictions of available launch vehicles and the possibilities of planned future vehicles have fueled the competition between monolithic primaries (with better optical quality) and segmented primaries (with larger apertures, but with diffraction, costs and figure control issues). Regardless of the current shroud sizes and lift capacities, these competing architectures share the need for rapid design tools. As part of the AMTD program a number of tools have been developed and tested to speed up the design process. Starting with the Arnold Mirror Modeler (which creates Finite Element Models (FEM) for structural analysis) and now also feeds these models into thermal stability analyses. They share common file formats and interchangeable results. During the development of the program, numerous trade studies were created for 4-meter and 8-meter monolithic primaries, complete with support systems. Evaluation of these results has led to a better understanding of how the specification drives the results. This paper will show some of the early trade studies for typical specification requirements such as lowest mirror bending frequency and suspension system lowest frequency. The results use representative allowable stress values for each mirror substrate material and construction method and generic material properties. These studies lead to some interesting relationships between feasible designs and the realities of actually trying to build these mirrors. Much of the traditional specifications were developed for much smaller systems, where the mass and volume of the primary where a small portion of the overall satellite. JWST shows us that as the aperture grows, the primary takes up the majority of the mass and volume and the established rules need to be adjusted. For example, a small change in lowest frequency requirement can change the cost by millions of dollars. The paper uses numerous trade studies created during the software development phase of the Arnold Mirror Modeler to illustrate the influences of system specifications on the design space. The future telescopes will require better performance, stability and documented feasibility to meet the hurdles of today's budget and schedules realities. AMTD is developing the tools, but the basic system planning mentality also has to adopt to the requirements of these very large and complex physical structures.

Arnold, William R., Sr.↗
DOE OSTI2020

Expedited Walkdowns and Preparation of Cost Estimates for Decontamination and Demolition of Excess Facilities - 20335

Lawrence Livermore National Security, LLC (LLNS) is the prime contractor responsible for managing and operating Lawrence Livermore National Laboratory (LLNL). The mission of the LLNL is to strengthen security of the United States through development and application of world-class science and technology to enhance the nation's defense, reduce the global threat from terrorism and weapons of mass destruction, and respond with vision, quality, integrity, and technical excellence to scientific issues of national importance. To accomplish its mission, LLNL must plan and manage its campus space and facilities to optimize use of its relatively small one-square-mile footprint. LLNL currently has numerous excess facilities that require decontamination and demolition (D and D). The LLNL Legacy Facility Program is responsible for stewardship and risk reduction programs to effectively manage these excess assets at LLNL. The Legacy Facility Program identified 10 excess facilities at LLNL that were candidates for demolition based on risks from further degradation of the facilities, potential exposure to hazardous materials, or need for removal to make way for new program facilities. The buildings range from a structure built in 1943 to serve as a US Navy drill hall during World War II, to a facility that provided neutrons to study material properties for the fusion energy program. The National Nuclear Security Administration (NNSA) appropriated FY19 funding for the development of Class 3 estimates for these 10 excess facilities that would be used to develop a Program Management Plan for funding consideration. Class 3 estimates are not conceptual, nor overly detailed, but adequate to be used for budget and appropriation purposes. Using existing strategic sourcing agreements, LLNL was able to organize a team of senior subject matter experts (SMEs) with diverse technical backgrounds across the Department of Energy (DOE) Complex to complete extensive process knowledge (PK) reviews and walk-downs of each excess facility and to deliver accurate and complete estimates under an expedited schedule (i.e., within eight weeks). To facilitate the expedited schedule, LLNL was fully prepared for the arrival of the JGMS team, which consisted of the following companies: J.G. Management Systems, Inc. (JGMS); Strata-G, LLC; and Michael Baker International. LLNL provided background and PK information on the excess facilities, pictures, supporting historical documentation, and radiological survey history as well as escorted access to the facilities. The JGMS team has previous experience supporting Program Management Plans for excess facilities at the Y-12 National Security Complex. The team mobilized to LLNL and performed the facility walk-downs from January 22-25, 2019. Using a methodical evaluation process, expertise, and experience, the team was able to deliver walk-down draft reports and estimates to LLNL before their February 8, 2019 deadline. LLNL then in turn reviewed, completed the estimates by adding waste management costs and other LLNL costs, and delivered the estimates to NNSA by February 15, 2019. The completed final reports, including draft D and D estimates, were delivered to LLNL before their March 6, 2019 deadline. The work was successfully completed ahead of the expedited schedule required by LLNL, resulting in a commendation from the client. This paper describes how the partnership and collaboration as a fully integrated team comprised of the prime contractor, LLNS, and the JGMS team successfully met the needs of the US government, resulting in the performance of expedited site walk-downs, the development of summary evaluation reports, and the preparation of draft Class 3 estimates and preliminary schedules for the D and D of 10 excess facilities at LLNL. The efforts of the team will enable the D and D of the first excess facility in the 2020-2021 time frame. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Transportation Hub Infrastructure Expansion: Decision Support Under Uncertainty

The Athena project (www.athena-mobility.org) has worked to investigate the relationship between the Dallas-Fort Worth Airport (DFW) and the greater Dallas area in order to better understand and therefore better inform future decision-making regarding the critical infrastructure that influence mobility between the airport and the city. Through this work, infrastructure related to curbside pickup and drop-off, parking, public transit, and the road network congestion were identified as critical to the operation of the DFW transportation hub. The infrastructure analysis and expansion aspect of the Athena project is focused on the restructuring of the CTA curb as a hierarchical curb and the building or repurposing of parking infrastructure as the interplay between these two areas. Many sources of uncertainty exist that may impact future airport and transportation hub operations, such as passenger volume growth, population demographic changes over time, electric vehicle (EV) adoption rates, and autonomous vehicle (AV) adoption rates. Due to these sources of uncertainty, we have selected for our research a modeling framework that can capture various types of uncertainty and hedge against those uncertainties in the optimization process. We analyze road network and curb congestion, the rise of transportation networking companies, trends in parking usage, existing policies around this infrastructure, airport revenue streams, and other contributing factors to enable infrastructure decision making with less uncertainty. To accomplish this wholistic analysis, we have developed a novel multi-stage, multi-period stochastic optimization model which considers the airport's decisions from 2025-2045 under different possible future macro trajectories and day-to-day variations in operational conditions captured as "annual representation of operations" scenarios with respective probabilities. This model has also been designed to leverage the outputs of various efforts under the Athena project to create a combined decision framework for infrastructure decisions. These various efforts include the route optimization model, the ASPIRES simulation, the mode choice model, and the SUMO traffic simulation. Our computational experiments of this system at scale have resulted in a working version of our infrastructure model which enables the explicit representation and consideration of various sources of uncertainty in the decision process to enable robust, flexible decision-making. This model has been effectively run on NREL's HPC system, Eagle, with large numbers of stochastic scenarios and shows promise as a scalable tool for robust consideration of uncertainties in airport planning. We have tested our model using 30,240 operational circumstances in total, resulting in a problem with more 200 million variables. This model was solved in several different configurations, and a workflow to simulate the performance of the infrastructure model results was developed and deployed. In general, our results indicate that a combination of remote parking, remote curb infrastructure, and dynamic pricing can generate revenue, reduce emissions, accommodate emerging technologies such as AVs and EVs, and manage airport passenger growth over time. We note the success of the proposed strategy depends on the data collection and forecasting abilities of DFW. We have also seen that the AV adoption by TNCs might necessitate larger amounts of remote curb. The results of this work inform strategies for airport infrastructure decision making, as well as demonstrate the value of an adaptable model, but also indicate that there are avenues remaining where further research would be of value.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗