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DOE OSTI2020

Multihour Stratospheric Flights with the Heliotrope Solar Hot-Air Balloon

Standard meteorological balloons can deliver small scientific payloads to the stratosphere for a few tens of minutes, but achieving multihour level flight in this region is more difficult. We have developed a solar-powered hot-air balloon named the heliotrope that can maintain a nearly constant altitude in the upper troposphere–lower stratosphere as long as the sun is above the horizon. It can accommodate scientific payloads ranging from hundreds of grams to several kilograms. The balloon can achieve float altitudes exceeding 24 km and fly for days in the Arctic summer, although sunset provides a convenient flight termination mechanism at lower latitudes. Two people can build an envelope in about 3.5 h, and the materials cost about $30. The low cost and simplicity of the heliotrope enables a class of missions that is generally out of reach of institutions lacking specialized balloon expertise. Here, we discuss the design history, construction techniques, trajectory characteristics, and flight prediction of the heliotrope balloon. We conclude with a discussion of the physics of solar hot-air balloon flight.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

CRADA 2022-03 Final Report: Advanced Bearing Materials for Harsh Service Conditions

Develop advanced bearing materials for hydrogen gas turbines and wind turbines. Two candidate materials have been selected based on Ames lab’s recent work on high entropy alloys and shape memory alloys. These materials are designed to exhibit a balance of hardness, strength, toughness, and corrosion resistance. The hydrogen diffusion coefficient in the NiTi based shape memory alloy is two order of magnitude lower than that of the conventional case hardened bearing steel. We plan to atomize these materials into powders, additive manufacture cylindrical bearings, then test these bearing for rolling-contact fatigue, corrosion properties, and hydrogen embrittlement. We are a vertically integrated team comprises of national labs, bearing manufacturers, raw material powders makers, and aircraft gas turbine manufacturer.

Argibay, Nicolas [Ames Laboratory (AMES), Ames, IA↗

DOE OSTI2023

Online Monitoring of Medium Voltage Cable Systems with Spread Spectrum Time Domain and Frequency Domain Reflectometry

In-service failures of wave energy convertor (WEC) cable systems can have a significant cost and power availability impact. Close parallel research 2019 data showed > 1B£ and 9 Terra-Watt-Hours associated with global off-shore wind (OSW) cable failures (Strang-Moran 2020). OSW is a closely related technology but currently is significantly cheaper than WEC technology. For wave energy to compete, the problem of reliable cable transmission must be mitigated. This project develops isolation technology to allow online high frequency reflectometry testing of medium voltage cables (1 to 10 kV and higher) without arcing or damage to the test instrument. Online spread spectrum time domain reflectometry (SSTDR) testing has been established for low voltage cable systems in the aircraft and rail industry and the ability to detect and locate cable flaws of interest is well understood. Extending reflectometry testing to medium voltage systems could enable detection of cable damage before failures occur thereby allowing repair and replacement of damaged cable segments to be scheduled and managed. The seedling project succeeded to pass and receive high frequency SSTDR signals onto a cable up to 1 kV using a parallel trace isolation circuit board that can be connected onto the test cable. The approach used a novel circuit design for which an invention disclosure has been filed. A proposed sapling project would extend the technology toward the higher operating voltages used by WEC systems, thereby enabling online SSTDR cable monitoring. The goal of the seedling project was to extend the capability of the ARENA cable/motor test bed to address medium voltages and to develop a high pass filter isolation architecture to protect the reflectometry instrument from the low frequency (DC – 60 Hz) line voltage while allowing the high frequency diagnostic signal to pass to and from the test instrument to the live line. Initial efforts focused on passive LCR filter circuits to reduce 60 Hz levels below 10 volts from a 10 kV line while allowing the MHz high frequency chirps to pass onto the cables and for mV signals to be detected. We discovered that the parasitic loss behavior of real high voltage components precluded this approach from working. An alternate approach was adapted for the electric field to couple between two parallel traces on a printed circuit board much like a radio-frequency coupler. The challenge here was and is to have the parallel traces close enough to each other to effectively pass the high frequency chirp onto the live line and receive any reflected signal from any encountered impedance change along the cable. This reflected signal will be in the mV range. The traces however must be far enough apart to not allow arcing on the board. A design with 3 mm spacing was determined to allow the high frequency signal to pass onto the live line and receive the mV signal back into the instrument while reducing the 60 Hz voltage amplitude by >80 dB (more than a factor of 10,000) without allowing arcing from across the parallel traces. This was confirmed by simulation and test.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Design and Performance of lithium-Ion Batteries for Achieving Electric Vehicle Takeoff, Flight, and Landing

Today, the burgeoning drive towards global urbanization with over half the earth’s population living in cities, has created major challenges with regards to intracity and intercity transit and mobility. This problem is compounded due to the fact that almost always urbanization and increase in standard of living drives individual automobile ownerships. Over 95% of automobiles are presently powered by some form of fossil fuel and as an unintended consequence, urban centers have also been centers for peak greenhouse gas emissions, a major contributor to global climate change. A revolutionary solution to this conundrum is flight capable electric automobiles or electric aerial vehicles that can tackle both urban mobility and climate change challenges. For such advanced electric platforms, energy storage and delivery component is the vital component towards achieving takeoff, flight, cruise, and landing. The requirements and duty cycle demands on the energy storage system is drastically different when compared to the performance metrics required for terrestrial electric vehicles. As the widely deployed lithium ion-based battery systems are often the primary go-to energy storage choice in electric vehicle related applications, it is imperative that performance metrics and specifications for such batteries towards areal electric vehicles need to be established. In this nascent field, there exists ample opportunities for battery material innovations, understanding degradation mechanism, battery design, development and deployment of battery control and management systems. Thus, this chapter comprehensively discusses battery requirements and identifies battery material chemistries suitable for handling aerial electric automobile duty cycles. The chapter also discusses the battery cell-level metrics pertaining to electrochemical, chemical, mechanical, and structural parameters. Furthermore, specific models for battery degradation, state of health (SOH), capacity and models for full cell performance and degradation are also discussed here. Finally, the chapter also discusses battery safety and future directions of batteries that would power these next generation urban electric aircrafts.

Amin, Ruhul↗

DOE OSTI2020

Assessment of Low-Altitude Atmospheric Turbulence Models for Aircraft Aeroelasticity

We investigate the dynamic aeroelastic response of large but slow aircraft in low-altitude atmospheric turbulence. To this end, three turbulence models of increasing fidelity, namely, the one-dimensional von Kármán model, the two-dimensional Kaimal model and full three-dimensional wind fields extracted from large-eddy simulations (LES) are used to simulate ambient turbulence near the ground. Load calculations and flight trajectory predictions are conducted for a representative high-aspect-ratio wing aircraft, using a fully coupled nonlinear flight dynamics/aeroelastic model, when it operates in background atmospheric turbulence generated by the aforementioned models. Comparison of load envelopes and spectral content, on vehicles of varying flexibility, shows strong dependency between the selected turbulence model and aircraft aeroelastic response (e.g. 58% difference in the predicted magnitude of the wing root bending moment between LES and von Kármán models). This is mainly due to the presence of large flow structures at low altitudes that have comparable dimensions to the vehicle, and which despite the relatively small wind speeds within the Earth boundary layer, result in overall high load events for slow-moving vehicles. Results show that one-dimensional models that do not capture those effects provide fairly non-conservative load estimates and are unsuitable for very flexible airframe design.

atmospheric turbulence↗

DOE OSTI2024

T-Type Modular DC Circuit Breaker (T-Breaker) for Future DC Networks

The developed T-Type Modular DC Circuit Breaker (T-Breaker) technology offers an all-in-one solution to challenges in DC networks. This includes swift fault detection and protection, power transient stability, and power quality improvement, achieved through the utilization of wide bandgap (WBG) power semiconductors and energy storage devices. The T-Breaker not only facilitates rapid fault current detection and interruption but also implements fault current limiting through active insertion of storage devices or by operating WBG devices in the saturation region. Additionally, with the assistance of energy storage devices, potential overvoltage issues on power devices induced by control signal misalignment can be mitigated. The T-Breaker can be regulated to perform shunt current injection/absorption using the vertical arm and series voltage insertion via the horizontal arm, thereby enhancing DC system stability during voltage or load power fluctuation transients. The OSU team and Raytheon team actively worked together on designing, fabricating, assembling, and testing of two T-Breaker prototypes. The first prototype is rated at 1 kV, 500 A with half-bridge (unipolar) structure to validate the T-Breaker concept. The second prototype is rated at 20 kV, 50 A with full-bridge (bipolar) topology which can reach an efficiency of 99.977%, realize a power density of 60.2 MW/m3, and eliminate the 500-A fault current with a fault response time of around 20 µs. The prototypes show great feasibility of adopting this technology in multiple applications including electrified aircraft, super charging stations, data centers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

CRADA Number NFE-21-08827 with DayLyte, Inc. (CRADA Final Report)

DayLyte Batteries is developing an aqueous Sodium-Air battery made with abundant materials while being half to a third the weight of Li-ion to power electric aircraft, electric vehicles and provide renewable energy on demand. To make this battery practical, DayLyte is developing a thin film ceramic Nasicon solid electrolyte amenable to rapid scaleup as well as a protective coating that will protect the solid electrolyte from 50wt% NaOH during the battery’s end-of-discharge while still allowing Na-ions to pass back and forth. If the thin film solid electrolyte and stable coating can be developed it will open the world to step change in battery performance all while not sacrificing the environment on the way. The project was designed to first focus on making and characterizing the Nasicon membrane followed by measuring its electrochemical performance, then assembling a full cell, optimizing its NaOH stability and then optimize the overall prototype design. Over the past two years, we have significantly improved the Nasicon film uniformity, demonstrated protective ligands that are stable in 50wt% NaOH by measuring no mass change with a quartz crystal microbalance, tested different heating methods like tube furnace and rapid heating and developed glassy carbon coatings on the current collector to prevent Nasicon-current collector alloying. We have found that getting film uniformity as measured by electrochemical impedance spectroscopy (EIS) is difficult because of different factors like surface roughness, deposition uniformity and heat treatment time and uniformity. The glassy carbon coating should significantly reduce the surface roughness and by tuning the coating conditions the film deposition uniformity improves and using an automated heating method should lead to much improved film uniformity.

25 ENERGY STORAGE↗

DOE OSTI2020

Development of aerosol activation in the double-moment Unified Model and evaluation with CLARIFY measurements

Representing the number and mass of cloud and aerosol particles independently in a climate, weather prediction or air quality model is important in order to simulate aerosol direct and indirect effects on radiation balance. Here we introduce the first configuration of the UK Met Office Unified Model in which both cloud and aerosol particles have “double-moment” representations with prognostic number and mass. The GLObal Model of Aerosol Processes (GLOMAP) aerosol microphysics scheme, already used in the Hadley Centre Global Environmental Model version 3 (HadGEM3) climate configuration, is coupled to the Cloud AeroSol Interacting Microphysics (CASIM) cloud microphysics scheme. We demonstrate the performance of the new configuration in high-resolution simulations of a case study defined from the CLARIFY aircraft campaign in 2017 near Ascension Island in the tropical southern Atlantic. We improve the physical basis of the activation scheme by representing the effect of existing cloud droplets on the activation of new aerosol, and we also discuss the effect of unresolved vertical velocities. We show that neglect of these two competing effects in previous studies led to compensating errors but realistic droplet concentrations. While these changes lead only to a modest improvement in model performance, they reinforce our confidence in the ability of the model microphysics code to simulate the aerosol–cloud microphysical interactions it was designed to represent. Capturing these interactions accurately is critical to simulating aerosol effects on climate.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

An overview of the ORACLES (ObseRvations of Aerosols above CLouds and their intEractionS) project: aerosol–cloud–radiation interactions in the southeast Atlantic basin

Southern Africa produces almost a third of the Earth's biomass burning (BB) aerosol particles, yet the fate of these particles and their influence on regional and global climate is poorly understood. ORACLES (ObseRvations of Aerosols above CLouds and their intEractionS) is a 5-year NASA EVS-2 (Earth Venture Suborbital-2) investigation with three intensive observation periods designed to study key atmospheric processes that determine the climate impacts of these aerosols. During the Southern Hemisphere winter and spring (June-October), aerosol particles reaching 3-5 km in altitude are transported westward over the southeast Atlantic, where they interact with one of the largest subtropical stratocumulus (Sc) cloud decks in the world. The representation of these interactions in climate models remains highly uncertain in part due to a scarcity of observational constraints on aerosol and cloud properties, as well as due to the parameterized treatment of physical processes. Three ORACLES deployments by the NASA P-3 aircraft in September 2016, August 2017, and October 2018 (totaling ~350 science flight hours), augmented by the deployment of the NASA ER-2 aircraft for remote sensing in September 2016 (totaling ~100 science flight hours), were intended to help fill this observational gap. ORACLES focuses on three fundamental science themes centered on the climate effects of African BB aerosols: (a) direct aerosol radiative effects, (b) effects of aerosol absorption on atmospheric circulation and clouds, and (c) aerosol–cloud microphysical interactions. This paper summarizes the ORACLES science objectives, describes the project implementation, provides an overview of the flights and measurements in each deployment, and highlights the integrative modeling efforts from cloud to global scales to address science objectives. Significant new findings on the vertical structure of BB aerosol physical and chemical properties, chemical aging, cloud condensation nuclei, rain and precipitation statistics, and aerosol indirect effects are emphasized, but their detailed descriptions are the subject of separate publications. The main purpose of this paper is to familiarize the broader scientific community with the ORACLES project and the dataset it produced.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Report on Lightning Simulation Standards and Facilities

Lightning strikes pose a significant threat to various forms of infrastructure and electrical equipment. Aircraft and high explosives are of particular interest due to the massive ramifications of the device being compromised due to exposure to lightning damage. However, due to lightning being a varying weather phenomenon, testing a device’s vulnerability to lightning is generally not as simple as simply exposing it to real world lightning. To consistently test a device’s ability to survive the worst-case scenario of lightning exposure, the effects of the most severe lightning strikes must be able to be reproduced consistently and measurably. One such facility for this purpose is the Sandia Lightning Simulator (SLS), which is designed to simulate the current waveform of a severe lightning flash. However, the SLS’s design and age lead to difficulties in its operation and inconsistencies in its output. The methodology used in other lightning simulation facilities may offer information on how to improve the SLS’s operation, or at the very least, expose the SLS’s hidden strengths. This report explores lightning simulation, lightning testing standards, and lightning simulation facilities.

42 ENGINEERING↗

DOE OSTI2020

Multicube retroreflector and retroreflector-based communication system

A “multicube” retroreflector may include “nested” corner cubes. Such a design combines the ease of fabrication of conventional corner cubes (e.g., stamping from a sheet) and the ability to easily and densely package them with a greater range of angles over which light will be reflected back towards the source. Such multicube retroreflectors may reflect 50% more light than corner cube retroreflectors. A retroreflector, or an array of retroreflectors, may be used as part of a communication system. A modulated retroreflector or an array thereof can form the basis of a unique communication system. For instance, by using a modulated retroreflector, or an array of such retroreflectors, a host system (e.g., an aircraft) can receive data from a remote system (e.g., a drone, an air-dropped sensor package, etc.) in a way that is difficult to intercept, and minimizes the power, computation, and antenna pointing requirements for the remote system.

42 ENGINEERING↗

DOE OSTI2025

Multi-phase Wireless Power Transfer with High Power Density Inductive Coils for Electric Drone Charging

Wireless charging of unmanned ground vehi-cles and aircraft has been proposed to increase charging reliability and security, allow for autonomous functionality, and either reduce battery size or increase continuous flight time. This paper proposes a three-phase Litz wire primary and a two-phase PCB secondary for high secondary-side power density considering misalignment tolerances, surface and volumetric power density, and coil sizing. Elec-tromagnetic 3D finite element analysis (FEA) simulations are conducted to study variation in mutual inductance and coupling coefficient with different secondary coil sizes and number of turns, horizontal and vertical misalignment between the primary and secondary, and a combination of both for a set of designs with the same rated power. Results indicate that receiver coils of reduced size relative to the primary can deliver rated power for increased power density and higher tolerance to misalignment.

Gastineau, Lucas [University of Kentucky]↗

DOE OSTI2024

Data Based Shock Test Specification

It is vital that avionic packages used for testing and certifying the reliability and safety of U.S. nuclear weapons with platform aircraft survive exposure to shock environments during transportation and delivery. The objective of this research was to characterize the response to these transportation shock environments delivering accurate shock test specifications in order to set laboratory programming material and device certification rigor. Responses to shock events were analyzed in the frequency domain via the Shock Response Spectrum (SRS). Shocks were then grouped based on respective behavior of maximum response accelerations which were pseudorandomly resampled and compared to test data to form test specifications based on the MinerPalmgren hypothesis. In addition to discovering significant over testing in current shock specifications, a new systematic, data-driven approach to designing shock specifications was formulated.

42 ENGINEERING↗

DOE OSTI2024

Fragmentation in Collisions of Snow with Graupel/Hail: New Formulation from Field Observations

Abstract Secondary ice production (SIP) has been attributed to the generation of most ice particles observed in precipitating clouds with cloud tops warmer than −36°C, from various aircraft- and ground-based field observations across the globe. One of the known SIP mechanisms is fragmentation during collisions among ice particles. It has been studied with our theoretical formulation, which has been applied in microphysical schemes of atmospheric models in a few studies. These have predicted an extensive impact on cloud glaciation and radiative properties. However, there has been a lack of experimental field studies, especially involving naturally falling snowflakes, to better understand this particular mechanism of SIP. This study reports the first field measurements with modern technology for fragmentation during collisions between naturally falling snowflakes and graupel/hail particles. This was observed with an innovatively designed portable chamber that was deployed outdoors in northern Sweden. Applying the observations from this field-based study, we optimized the existing formulation for predicting numbers of fragments from collisions of snow with graupel/hail. The observations show the average numbers of fragments per collision for dendritic (3–12 mm) and nondendritic (1–3 mm) snow were about 12 and 1, respectively. This represents a boost of predicted fragment numbers relative to our original formulation published in 2017. The updated formulation for breakup in ice–ice collisions can be implemented in the microphysical schemes of atmospheric models.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Evaluation of Microreactor Inhalation Dose Consequences

The new generation of microreactors are intended to provide useful, very reliable and safe safe energy for a variety of applications such as supplying to remote locations. Microreactors range from less than 1 MW th to more than 20 MW th . A range of technologies is being considered, including variations in neutron energy spectrum (fast or thermal), variations in primary and secondary coolant choices (e.g. metal cooled, gas cooled, and unique power cycle reactors. The reactors tend to use new fuel forms and types with unique benefits such as metal or TRISO fuel for higher fuel density and safety, respectively. The notional image of a microreactor is a reactor that fits in a seavan or intermodal shipping container. This would allow conventional shipping options, including aircraft, and match other mobile power sources. A development of a capability to test these reactors is needed, whether in a facility or in an open area. INL is in the process of determining acceptable test areas for these various reactors and an understanding of potential bounding consequences is important in informing siting and required infrastructure capability decisions. This ECAR considers the bounding release fractions of these types of reactors at 20 MW th and documents the dose consequences to the public and collocated worker. This is a scoping analysis for the generalized type of reactor, and the analysis will be refined based on the specific reactor design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Atmospheric Carbon and Transport – America (ACT-America) Data Sets: Description, Management, and Delivery

The ACT-America project is a NASA Earth Venture Suborbital-2 mission designed to study the transport and fluxes of greenhouse gases. The open and freely available ACT-America data sets provide airborne in situ measurements of atmospheric carbon dioxide, methane, trace gases, aerosols, clouds, and meteorological properties, airborne remote sensing measurements of aerosol backscatter, atmospheric boundary layer height and columnar content of atmospheric carbon dioxide, tower-based measurements, and modeled atmospheric mole fractions and regional carbon fluxes of greenhouse gases over the Central and Eastern United States. In this study, we conducted 121 research flights during five campaigns in four seasons during 2016–2019 over three regions of the US (Mid-Atlantic, Midwest and South) using two NASA research aircraft (B-200 and C-130). We performed three flight patterns (fair weather, frontal crossings, and OCO-2 underflights) and collected more than 1,140 h of airborne measurements via level-leg flights in the atmospheric boundary layer, lower, and upper free troposphere and vertical profiles spanning these altitudes. We also merged various airborne in situ measurements onto a common standard sampling interval, which brings coherence to the data, creates geolocated data products, and makes it much easier for the users to perform holistic analysis of the ACT-America data products. Here, we report on detailed information of data sets collected, the workflow for data sets including storage and processing of the quality controlled and quality assured harmonized observations, and their archival and formatting for users. Finally, we provide some important information on the dissemination of data products including metadata and highlights of applications of ACT-America data sets.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Integrating Characteristic Arctic Vegetation in a Land Surface Model Improves Representation of Carbon Dynamics Across a Tundra Landscape

Arctic warming is altering vegetation and carbon dynamics with global implications, yet Earth System Model (ESM) predictions in the Arctic remain highly uncertain, in part due to historically limited data for model parameterization and validation. As such, ESMs typically represent Arctic ecosystems in an oversimplified manner. Recently, nine plant functional types (PFTs) designed to realistically represent tundra vegetation were integrated into the Energy Exascale Earth System Model (E3SM) Land Model (ELM) and parameterized using plot-scale observations from a single site. Additional evaluation was needed to determine their transferability across the Arctic. Here, in this study, we evaluated whether refined representation of tundra vegetation improved model accuracy by conducting spatially explicit 100 × 100 m resolution ELM simulations on Alaska's Seward Peninsula. Simulations with the default two-PFT configuration and with the nine Arctic-specific PFTs were benchmarked against observations of net ecosystem exchange, gross primary production, and aboveground biomass from multiple data streams including an eddy covariance flux tower, flux chambers, and aircraft and unoccupied aerial system hyperspectral remote sensing. Evaluation revealed that Arctic-specific PFT simulations produced more realistic landscape-level carbon exchanges, and better captured observed heterogeneity in biomass and productivity, explaining 60%–70% of spatial variance (R 2 = 0.6–0.7) compared to just 12%–18% (R 2 = 0.12–0.18) with the default configuration. However, the refined model failed to reproduce observed aboveground biomass for highly productive alder-willow communities, requiring further evaluation of carbon allocation parameterizations for tall shrubs that are increasingly expanding across tundra landscapes. Our results demonstrate that enhanced representation of vegetation heterogeneity boosts predictive understanding of tundra carbon dynamics, facilitating regional to pan-Arctic model and remote-sensing scaling.

Murphy, Bailey A. [Oak Ridge National Laboratory (↗

DOE OSTI2022

Hybrid Solid Oxide Fuel Cell/Gas Turbine Model Development for Electric Aviation

A thermodynamic model was developed and validated to analyze a high-performance solid oxide fuel cell and gas turbine (SOFC-GT) hybrid power system for electric aviation. This study used a process simulation software package (ProMax) to study the role of SOFC design and operation on the feasibility and performance of the hybrid system. Standard modules, including compressor, turbine, heat exchanger, reforming reactor, and combustor were used from the ProMax tool suite while a custom module was created to simulate the SOFC stack. The model used an SOFC test data set as an input. Additional SOFC stack performance effects, such as pressure, temperature, and utilization of air and fuel, were added from open source data. System performance predictors were SOFC specific power, fuel-to-electricity conversion efficiency, and hybrid system efficiency. Using these input data and predictors, a static thermodynamic performance model was created that can be modified for different system configurations and operating conditions. Prior to creating the final aircraft performance model, initial demonstration models were developed to validate output results. We used the NASA SOFC model as a benchmark, which was created with their Numerical Propulsion System Simulator (NPSS) software framework. Our output results matched within 1% of both the NASA model and open source SOFC performance data. With confidence gained in the accuracy of this model, a 1-MW SOFC-GT hybrid power system was constructed for an aircraft propulsion concept. Overall hybrid system efficiencies of > 75% FTE were observed during standard 36,000 feet cruise flight conditions.

30 DIRECT ENERGY CONVERSION↗