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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Motorette Thermal Performance Testing and Modeling for an Electric Motor with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

This paper discusses the design, build and test of a motorette to characterize the thermal performance of an additively manufactured coil integrated with heat pipes. The motorette is powered using a variable frequency AC power supply and cooled through two independent cooling systems. The first cooling system cools the stator core using forced convection of air flowing over a finned heat sink mounted on the stator outer diameter. The second cooling system cools the heat pipes using forced convection of 50-50 water ethylene glycol (WEG) mixture flowing through condenser chambers. A 3D thermal FEA model of the setup is built and heat transfer coefficients (HTC) of convective boundaries are computed using coolant flow rates from test data and empirical equations. Temperature at locations on the coil and heat sink are recorded and compared to thermal model predicted values. A maximum temperature error of 22.7% occurs at 180ARMS and 800 Hz operating point for the AM dual coil. The thermal model provides higher temperatures compared to test results and hence it is on the conservative side but in general, there is good correlation between test and model results. Lastly, opportunities for improvement to both test data measurement and 3D thermal FEA modeling are discussed.

additive manufacturing↗
DOE OSTI2024

Design of High-Power Polyphase PCB Coil Systems for Wireless Power Transfer

Printed circuit board (PCB) coils have been proposed prior for implementation as inductive wireless charging coils to minimize size and cost. Utilization of PCBs can allow for a reduced cost, improved manufacturability, and a wide range of geometric customization options. To circumvent material limitations on insulation and thermal performance, parallel paths can be implemented to divide the current per path accordingly. Within this paper, an unconventional high-power PCB coil is designed employing all possible techniques for wiring with axial and radial parallel paths with equivalent transposition to minimize circulating currents. Design studies are simulated in 3D finite element analysis (FEA) to evaluate imbalance between phases with and without transposition. Two experimental prototype coils were fabricated with measurements for self-inductance and mutual inductance between phases. These measurements were validated to be sufficiently consistent with FEA results. Additionally, a method is proposed for a two-step optimization of coupling coefficient and coil losses.

Lewis, Donovin D.↗
DOE OSTI2025

Design of a Structure for Assembly and Cooling the Magnet of the Next-Generation 45 GHz ECR Ion Source MARS-D

Here, the current Electron Cyclotron Resonance Ion Sources (ECRISs), constructed with Nb-Ti wires and the conventional racetrack-and-solenoid structure, have achieved operating frequencies up to 28 GHz and utilized about 90% of the critical current of the Nb-Ti wire. A Mixed Axial and Radial field System Demonstrator (MARS-D) is being developed at Lawrence Berkeley National Laboratory (LBNL). This system, which consists of an innovative hexagonal Closed-Loop Coil (CLC) and a set of solenoids, can generate higher magnetic fields (up to 150% ) while requiring only about 50% of the superconducting wire, enabling Nb-Ti wires to be used in the next-generation 45 GHz ECRIS. However, the assembly and cooling of such an efficient and compact magnet are particularly challenging due to the small radial gap between the CLC and solenoids, as well as the tight operating temperature margin. To address these challenges, a structure was developed that combines a three-section radially split solenoid mandrel with a series of shrink-fit reinforcement rings and cooling channels. This paper presents the detailed structure, manufacturing method, assembly procedure, impregnation method, mechanical Finite Element Analysis (FEA) comparison, and thermal FEA comparison.

ECR ion sources↗
DOE OSTI2026

C‐Cracking of Brittle‐Material Spheres From Eccentric Hertzian Contact

Contact of brittle-material spheres can occur while they are manufactured, handled, or used in operation as roller elements or in deformably processed composite material. Statistically, the directional contact between two spheres will nearly always be oblique or eccentric in an unconfined and mobile sphere population. Although analyses of oblique contact exist, the portrayal of its maximum (tensile) first principal stress ( S 1 ) field is lacking. This information is needed for improved judgment of the prospect of crack initiation. Given these, the S 1 due to eccentric contact and subsequent crack initiation was analyzed using finite element analysis (FEA) and corroborative demonstration of c-crack creation. The FEA shows that an asymmetric S 1 field is created about the contact patch and is caused by superimposed shear intrinsic to eccentric contact. A crack will initiate if the maximum S 1 exceeds the material's tensile strength, and its field will cause the crack to propagate and arrest to form a C-shaped crack, or c-crack. C-crack initiation trends with lower applied forces, with greater amount of contact eccentricity, higher coefficient of friction, and smaller spherical radius. Finally, these metrics deserve recognition, especially when c-cracked brittle-material spheres are used in a system whose functionality or reliability is potentially compromised by the c-cracks.

Hertzian contact↗
DOE OSTI2024

Fabrication, Modeling, and Testing of a Prototype Thermal Energy Storage Containment

Increasing penetration of variable renewable energy resources requires the deployment of energy storage at a range of durations. Long-duration energy storage (LDES) technologies will fulfill the need to firm variable renewable energy resource output year round; lithium-ion batteries are uneconomical at these durations. Thermal energy storage (TES) is one promising technology for LDES applications because of its siting flexibility and ease of scaling. Particle-based TES systems use low-cost solid particles that have higher temperature limits than the molten salts used in traditional concentrated solar power systems. A key component in particle-based TES systems is the containment silo for the high-temperature (>1100 degrees C) particles. This study combined experimental testing and computational modeling methods to design and characterize the performance of a particle containment silo for LDES applications. A laboratory-scale silo prototype was built and validated the congruent transient finite element analysis (FEA) model. The performance of a commercial-scale silo was then characterized using the validated model. The commercial-scale model predicted a storage efficiency above 95% after 5 days of storage with a design storage temperature of 1200 degrees C. Insulation material and concrete temperature limits were considered as well. The validation of the methodology means the FEA model can simulate a range of scenarios for future applications. This work supports the development of a promising LDES technology with implications for grid-scale electrical energy storage, but also for thermal energy storage for industrial process heating applications.

clean energy↗
DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Thermomechanical Modeling and Analysis of a High-Temperature Light Trapping Planar Cavity Receiver

Solar energy harnessed through concentrating solar power (CSP) systems offers a promising path to sustainable energy production, with the efficiency and longevity of these systems relying on key components like solar receivers. This study analyzes the thermomechanical behavior of an innovative enclosed light-trapping solar receiver optimized for particle heating applications. The receiver utilizes sheet metal alloys to form enclosed cavities that reflect and trap incoming solar flux, as well as enclosed channels that contain fluidized particle beds absorbing solar heat. Finite element analysis (FEA) is applied to predict the receiver's thermomechanical performance under extreme solar flux conditions. Temperature distributions from a thermal model simulating a multi-panel assembly at steady state are input into the FEA thermomechanical model for stress analysis. A key aspect of the analysis focuses on evaluating creep-fatigue damage, with a design target of achieving a 30- year service life. Various stress relief techniques are also proposed to extend the receiver's service life. The results highlight the significant impact of the particle-to-wall heat transfer coefficients (HTCs), ranging from 800 W/m2*K to 1400 W/m2*K. The 800 W/m2*K case shows a maximum von Mises stress of 164 MPa, while the 1400 W/m2*K case reduces it to 150 MPa. The creep life increases from 4,000 hrs in the 800 W/m2*K case to over 100,000 hrs in the 1400 W/m2*K case with Inconel 740H used, indicating that higher HTCs reduce stress and extend lifespan. This research advances the design of high-efficiency, low-stress solar receivers for particle-based thermal energy storage in CSP and industrial heating applications.

concentrating solar power↗
DOE OSTI2020

Experimentally Validated Computational Modeling of Creep and Creep-Cracking for Nuclear Concrete Structures

In a Nuclear Power Plant, one of the most important components is the concrete nuclear reactor cavity, which serves both a structural and protective function as the biological radiation shield. Given that creep has been identified as a major knowledge gap in the assessment of nuclear structures (NUREG/CR-7153), this work helps to further the understanding of creep behavior of massive concrete containment structures for decades to enable safe and long-term operation of these facilities. This project has developed a robust, experimentally validated model to predict creep in nuclear concrete structures for up 60 years using short-term creep data thereby enabling a longer service life of critical facilities and early detection of structural failure. The work presented in this report is a pairing of computational and experimental methods. For the first time, the time temperature superposition (TTS) principle was successfully used to generate a uniaxial creep compliance master curve to predict mortar creep response for up to 22,500 days (nearly 60 years) at a reference temperature of 20°C. These data were used as input into finite element analysis (FEA) codes that use highly realistic random, 3D concrete microstructures from reconstructed coarse limestone aggregates. Finite element analysis performed provides the ability to quickly upscale mortar viscoelastic behavior to long-term concrete creep/relaxation data. A master creep compliance curve, constructed from the TTS principle, spanning 27 years, was used to validate two and a half decades of simulated concrete creep. Concurrently, three different simulated wall specimens were designed to mimic the behavior of post-tensioned concrete nuclear containment facility vessel walls over time as a result of concrete creep. The specimens were designed with different thicknesses, transverse and longitudinal reinforcement ratios, and level of post-tensioning stress. Each specimen contained various instrumentation to measure internal concrete temperature, concrete strain, and post-tensioning strain hourly for over 3 years. The concrete creep model developed in this project, based on the FEA concrete simulations, was applied to simulate the structural-scale experiments of prestressed concrete walls conducted in this project using the Grizzly code. These models can represent the effects of reinforcing and prestressing. Although there are some discrepancies with the experimental data, the model can predict the overall trends of the creep response in these experiments. One of these experimental models was also applied to an extended time to demonstrate how the findings from this study can be used to predict the behavior of actual structures of interest that have been in service for extended periods of time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Ribbon Wrinkling Origin and Its Effect on Tape-Wound Core Shape

Improved understanding of advanced manufacturing techniques is needed to fabricate next- generation soft magnetic tape-wound cores. These utilize metal amorphous nano-composites (MANCs) in the form of long thin ribbons. MANCs exhibit attractive soft magnetic properties for use in high frequency and high power density magnetic components. Of particular interest here, the permeability and hysteresis of MANC ribbons can be tuned in a strain annealing process. An unexpected consequence is that wider ribbons develop longitudinal wrinkle patterns. This can substantially reduce the tape-wound core stacking factor. However, when winding a wrinkled ribbon into a toroidal core, the wrinkles can completely flatten, or crinkle. By this phenomenon, the stacking factor can be recovered. To understand the crinkling effect we have developed analytical and finite element analysis (FEA) models. Experiments with known boundary conditions demonstrate the transition from wrinkled to crinkled versus winding curvature. The models utilize an elastic modulus measured via ribbon tensile testing and a ribbon thickness value measurement made by profilometry. The analytical model provides insight into the crinkling effect but cannot explain the length of the transition region from wrinkling to crinkling. With FEA, we successfully predict the transition region and depending on wrinkling amplitude can determine when a ribbon will wind into a useable core. Such mechanics-based insight provides critical feedback for allowable processing parameters in the strain annealing process.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Metallurgical Analysis and Forward Modeling of Weld Distortion in SMR Containment Vessels

This work aimed to apply Sandia’s expertise in metallurgy and modeling to enable the use of hybrid laser arc welding for building nuclear reactor containment structures, via a collaboration with Holtec International. Experimental observations were coupled with finite element analysis to resolve microstructure development, mechanical properties, distortion, and residual stress in welds relevant to the production of the Holtec SMR-160. High residual stresses were observed in welds that were not subjected to preheat. Meanwhile, the microstructure of the welds generally exhibited a narrow heat affected zone relative to conventional arc welds. FEA appeared to be effective in simulating the thermal/mechanical conditions that occur during hybrid laser arc welding of simplified and instrumented test welds. Subsequently, FEA was used to perform sensitivity analyses for various weld geometries that would be prohibitively costly to assess with physical experiments. Insights from the study were used to inform Holtec’s welding process, and successful production welds were performed in 2025.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗
DOE OSTI2024

The Function of Horn Ridges for Impact Damping

This study explores the damping effects of ram horn ridges on mechanical impacts resulting from ramming. We measured the amplitudes and frequencies of ridges along the axial (pitch) direction of the ridges of ram horns obtained from eight specimens across six different species. While the horns shared a similar spiral-shaped pattern with surface ridges, our findings show variations among the horns, including ridge spacing and growth trends. Additionally, we employed finite element analysis (FEA) to compare a ridged horn model with a non-ridged counterpart to provide an understanding of the damping characteristics of the surface ridges. Our FEA results reveal that the ridged horn decreased the initial ramming pressure by 20.7%, increased the shear stress by 66.9%, and decreased the axial strain by 27.3%, the radial strain by 16.7%, and the shear strain by 14.3% at a 50 ms impact duration compared to those of the non-ridged horn. The damping ratio was increased by 7.9% because of the ridges. This study elucidates three primary functions of the different species of ram horns’ spirals and ridges: (1) to transfer longitudinal waves into shear waves, (2) to filter shear waves, and (3) to stabilize the structure by mitigating excessive strain.

bio-inspired design↗
DOE OSTI2022

Simulation and Modeling of Optical Properties of U, Th, Pb, and Co Nanoparticles of Interest to Nuclear Security Using Finite Element Analysis

In this work, the optical characteristics of uranium (U), lead (Pb), cobalt (Co), and thorium (Th) nanoparticles are fashioned and simulated employing the finite element analysis (FEA) approach concerning multiple particle sizes. Applying finite element analysis, it was found that the simulated absorption peaks of electronic excitations of nuclear nanoparticles are red-shifted from 365 nm to 555 nm for U; from 355 nm to 550 nm for Pb; from 415 nm to 610 nm for Co; and from 350 nm to 540 nm for Th, comparing expanding particle sizes from 60 nm to 100 nm (except for Co, which varied from 70 nm to 100 nm). The FEA-simulated optical band gap energies and far-field radiation patterns were also obtained for nuclear materials. The simulation approach in this research enables the prediction of optical properties and design of nuclear materials before manufacture for nuclear security applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Evaluation of High-Temperature Martensitic Steels for Heavy-Duty Diesel Piston Applications

Five different commercially available high-temperature martensitic steels were evaluated for use in a heavy-duty diesel engine piston application and compared to existing piston alloys 4140 and microalloyed steel 38MnSiVS5 (MAS). Finite element analyses (FEA) were performed to predict the temperature and stress distributions for severe engine operating conditions of interest, and thus aid in the selection of the candidate steels. Complementary material testing was conducted to evaluate the properties relevant to the material performance in a piston. The elevated temperature strength, strength evolution during thermal aging, and thermal property data were used as inputs into the FEA piston models. Additionally, the long-term oxidation performance was assessed relative to the predicted maximum operating temperature for each material using coupon samples in a controlled-atmosphere cyclic-oxidation test rig. A current commercial steel piston alloy, quenched and tempered martensitic steel 4140, was tested in a single-cylinder research engine for a baseline oxidation and mechanical performance assessment using an abbreviated (50h) durability test plan. The predicted suitability of a candidate piston material in an engine is primarily based on its elevated temperature strength, oxidation resistance, and the complex influence of thermal conductivity, the latter of which is substantially lower for the candidate materials considered in this research relative to the traditional alloys. Although the lower thermal conductivity causes the candidate alloys to operate in higher temperature ranges under identical engine operating conditions and piston geometries, increasing the likelihood of partially or completely negating their strength and oxidation resistance advantages relative to 4140 and MAS steels, this evaluation indicates that several of the candidate piston alloys are predicted to enable improved oxidation resistance under more severe engine operating conditions relative to the current piston materials. However, further evaluation is required to determine if the elevated temperature fatigue strength and durability of these alloys are suitable for more severe engine conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fourier Analysis Method for Wireless Power Transfer Coil Design

Wireless power transfer (WPT) systems for Electric Vehicles (EVs) are designed to meet specifications such as stray field, power transfer, efficiency, and ground clearance. Typical design approaches include iterative analysis of predetermined coil geometries to identify candidates that meet these constraints. This work instead directly generates WPT coil shapes and magnetic fields to meet specifications and constraints through the optimization of Fourier basis function coefficients. The proposed Fourier Analysis Method (FAM) applies to arbitrary planar coil geometries and does not rely on iterative finite-element analysis (FEA) simulations. This flexibility allows for rapid design evaluation across a larger range of coil geometries and design specifications. A prototype coil is built to compare FAM outputs to experimental measurements and FEA simulations. The FAM is then used to illustrate the tradeoff of coil current and stray field for a given power level showing that the method is capable of generating optimized coil shapes to meet arbitrary field constraints.

Foote, Andrew↗
DOE OSTI2024

ECAR-6580 Rev 0 ASME Section III, Division 5 Analysis of the MARVEL PCS and GVS Top Corner

The purpose of this Engineering Calculations and Analysis Report (ECAR) is to document the structural evaluation for part of the Microreactor Applications Research Validation and Evaluation (MARVEL) Primary Coolant System (PCS) and Guard Vessel System (GVS). For the PCS this relates specifically to the Distribution Plenum (DP), The Intermediate Heat Exchanger (IHX), and the Upper Downcomer (UD). For the GVS, this will include only the top corner that is machined into the DP Top Plate. These components will be evaluated using the 2021 version of ASME Section III, Division 5 [1] which is a design code that governs the construction of vessels, storage tanks, piping, pumps, valves, supports, core support structures and nonmetallic core components for use in high temperature reactor systems and their supporting systems. Materials at high temperature are subject to creep and fatigue mechanisms that require additional analyses that aren’t covered in ASME Section III, Division 1 rules. Division 5 contains two approaches: elastic or inelastic, however, additional Code Cases specific to Division 5, allow for an Elastic-Perfectly Plastic (EPP) approach. The components analyzed in this ECAR will use a combination of the elastic and EPP approach. Only Design and Service Levels A and B are evaluated in this ECAR. Service Level D evaluations for the entire PCS are documented in ECAR-6564, “MARVEL Project Primary Coolant System Pressure Vessel Stress Documentation” [2] and for the entire GVS are documented in ECAR-6574, “MARVEL Guard Vessel System FEA and ASME Analysis” [3]. The Design and Service Level A and B analyses for the PCS Downcomer piping and Core Barrel are documented in ANL-24/36, "Engineering Calculations and Analysis of the Core Barrel and Downcomer Piping in the MARVEL PCS” [4], and the GVS (except for the top corner) is in ECAR-6574, “MARVEL Guard Vessel System FEA and ASME Analysis.” See Section 2.0 for more detail on the analysis boundaries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2023

ECAR-7210 Rev 0 Steady-state Thermo-mechanical Analysis of the MARVEL Fuel Bundle

This document reports the steady-state thermal-hydraulic and static mechanical analyses of the MARVEL micro-reactor core. The objective of this work is to investigate whether fuel-to-fuel contact could occur due to the thermal deformation of the fuel cladding during the normal operation and to assess the resulting impact on the peak cladding temperatures (PCT) if contact occurs. The scope of the work consists of three computational tasks. First, a conjugate heat transfer analysis using computational fluid dynamics (CFD) model was performed to evaluate the PCTs during normal operating conditions. Second, a finite element analysis (FEA) using the cladding temperature field obtained from the CFD analysis was performed to evaluate the thermal deformation of cladding and determine the occurrence of fuel-to-fuel contact. Finally, a CFD analysis of FEA-informed fuel-to-fuel gap (represented by a conservative 0.05 mm uniform gap) was performed to evaluate whether the PCT exceeds the safety criteria.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2023

Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.

42 ENGINEERING↗