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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 OSTI2021

Structural Design Variations in Beetle Elytra

Abstract Beetles typically use their protective wing coverings or elytra to shield their membranous hindwings from the environment. Elytra in some terrestrial species have evolved a greater protective role capable of shielding the organism from powerful antagonistic predators. The structure–function relationships of these biological composites identify how architectural and chemical variations of the cuticle are tuned to create light‐weight, impact resistant composites. Specifically, the elytral structures of a tree dwelling beetle capable of flight, Trypoxylus dichotomus , and a terrestrial beetle incapable of flight, Phloeodes diabolicus , are compared to understand how their varied environmental needs forged the elytra to facilitate fight or resist fatal predator strikes. Mechanical and microstructural analysis reveals P . diabolicus has a harder, stiffer elytra that incorporate through‐thickness fibers to resist greater mechanical stresses imposed by bending and puncture. Conversely, the elytra of T . dichotomus have a compliant structure with large voids that facilitates localized deformation. Variations in flexural strength and puncture resistance remain attributed to P . diabolicus possessing a thicker cuticle with a greater degree of cross‐linking and an increased amount of endocuticular layers. These findings may provide useful insight into the design and manufacturing of composite materials for use in light‐weight or energy‐absorbing applications.

Rivera, Jesus↗
DOE OSTI2023

Formation and Shape Changing of Conductive Helical Ribbons via Deposition of Highly Stressed Films on Mechanically Responsive Substrates

Abstract This work demonstrates that the electrodeposition of highly stressed films on compliant ribbons is a robust process to obtain helical structures with excellent mechanical stability and potentially high thermal and electrical conductance. Electrodeposition on end‐tethered ribbons alters their axial and bending stiffness while imparting mechanical stress to drive the formation of a helix with a microscale diameter and pitch in a controlled and scalable manner. The process generates helices with diameters and pitches between 80 and 200 µm and lengths as large as several millimeters. The approach is amenable to parallel processing a large number of 3D structures on any substrate, including large‐area semiconductor wafers. This phenomenon is explained in terms of the change of stress gradients as material is added. Applications of the fabricated helices include antennas, metamaterials, and slow‐wave structures in frequency ranges not previously attainable.

Chemistry↗
DOE OSTI2023

Millimeter-Thick Liquid Crystalline Elastomer Actuators Prepared by-Surface-Enforced Alignment

Here, liquid crystalline elastomers (LCE) are thermally cyclable, compliant actuators with compelling mechanical properties. The large and programmable deformation of LCE has led to numerous functional examinations spanning optics, medical devices, and robotics. A well-established method to prepare complex LCE actuators is to utilize surface-enforced photoalignment. Herein, a facile and scalable approach is reported to circumvent the physical limits of surface-enforced alignment (e.g., samples that are 50 µm or less) to amplify the achievable force output in LCE. Applying an approach termed direct layering, the thermomechanical response of LCE elements prepared with +1 disclination patterns in a range of compositions and thicknesses is contrasted. The design and preparation of +1 disclination patterns and arrays is explored to assess the contribution of sample geometry and overlap to deformation and force output. The methodology detailed in this contribution allows for the preparation of elements ≈1 mm in thickness that are capable of actuating large objects. Furthermore, the fabrication of these elements uniquely enables the realization of mechanical instabilities to hasten the actuation rate in response to thermal change and to enable leaping.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Extreme Energy Dissipation via Material Evolution in Carbon Nanotube Mats

Abstract Thin layered mats comprised of an interconnected meandering network of multiwall carbon nanotubes (MWCNT) are subjected to a hypersonic micro‐projectile impact test. The mat morphology is highly compliant and while this leads to rather modest quasi‐static mechanical properties, at the extreme strain rates and large strains resulting from ballistic impact, the MWCNT structure has the ability to reconfigure resulting in extraordinary kinetic energy (KE) absorption. The KE of the projectile is dissipated via frictional interactions, adiabatic heating, tube stretching, and ultimately fracture of taut tubes and the newly formed fibrils. The energy absorbed per unit mass of the film can range from 7–12 MJ kg −1 , much greater than any other material.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Atomic force microscopy and scanning electron microscopy characterization of the controlling of surface morphology of epoxy‐amine‐cured spin‐coated films

Abstract Atomic force microscopy (AFM) was successfully used to study spin‐coated, amine‐cured epoxy film microstructure and morphology. The air‐epoxy and epoxy‐substrate interfaces were examined using tapping‐mode height and phase imaging AFM. The impact of relative humidity on the morphology and microstructure of the surfaces was determined. AFM was able to elucidate the changes on the surface as relative humidity during processing increased. It was observed that large nodular formations formed on the epoxy surface expose to the air but not epoxy surface formed on the substrate in addition to varying regions of more or less compliant structures, which was attributed to carbamate formation caused by the amine curing agent reaction with atmospheric CO 2 . Scanning electron microscopy (SEM) was used to further elucidate interface and interphase morphology of spin‐coated epoxies. Experimentation also demonstrated that post‐curing above the glass transition did not change the morphology structure, suggesting surface structures are “locked‐in.” SEM was used to further elucidate how the interface and interphase change with changing environmental conditions at both the air‐epoxy and epoxy‐substrate interface/interphases, including the impact of atmospheric CO 2 on Marangoni cell formation.

Shenk, Timothy M.↗
DOE OSTI2023

Earthquake-induced impact of base-isolated buildings: theory, numerical modeling, and design solutions

Earthquake shaking more intense than that used to size the horizontal clearance between a base–isolated building and near–rigid perimeter moat wall will result in hard impact, producing high–frequency, high–amplitude acceleration response in the structure and supported equipment. Herein this paper provides a design solution for the damaging effects of hard impact by installing a compliant engineered element in the load path between the base–isolated building and the moat wall, resulting in soft impact and a much smaller acceleration response. The engineered element assumed herein is a commercial–off–the–shelf marine fender with mechanical properties determined by physical testing. The attachment of a flexible engineered element, with well–defined stiffness and damping, to a near–rigid moat wall, simplifies the numerical modeling of the building–moat wall system and eliminates the need to bound the lateral stiffness of the wall for impact calculations. The simple model of the engineered element can be implemented in commercial finite element codes. Theory is developed for two–sided impact of a single–degree–of–freedom oscillator. Analytical solutions are derived for the shifted first–mode frequency of the impacted oscillator and for its free–vibration response. The shifted first–mode frequency is a function of the composite lateral stiffness of the isolator–engineered element assembly and its earthquake–induced displacement. Local peaks in the spectral response of the impacted oscillator form at odd integer multiples of the shifted first–mode frequency. The analytical solutions can be used to verify, in part, the numerical model used for impact analysis.

42 ENGINEERING↗
DOE OSTI2024

A prototype scintillator real‐time beam monitor for ultra‐high dose rate radiotherapy

Background: FLASH Radiotherapy (RT) is an emergent cancer RT modality where an entire therapeutic dose is delivered at more than 1000 times higher dose rate than conventional RT. For clinical trials to be conducted safely, a precise and fast beam monitor that can generate out-of-tolerance beam interrupts is required. This paper describes the overall concept and provides results from a prototype ultra-fast, scintillator-based beam monitor for both proton and electron beam FLASH applications. Purpose: A FLASH Beam Scintillator Monitor (FBSM) is being developed that employs a novel proprietary scintillator material. The FBSM has capabilities that conventional RT detector technologies are unable to simultaneously provide: (1) large area coverage; (2) a low mass profile; (3) a linear response over a broad dynamic range; (4) radiation hardness; (5) real-time analysis to provide an IEC-compliant fast beam-interrupt signal based on true two-dimensional beam imaging, radiation dosimetry and excellent spatial resolution. Methods: The FBSM uses a proprietary low mass, less than 0.5 mm water equivalent, non-hygroscopic, radiation tolerant scintillator material (designated HM: hybrid material) that is viewed by high frame rate CMOS cameras. Folded optics using mirrors enable a thin monitor profile of ∼10 cm. A field programmable gate array (FPGA) data acquisition system generates real-time analysis on a time scale appropriate to the FLASH RT beam modality: 100–1000 Hz for pulsed electrons and 10–20 kHz for quasi-continuous scanning proton pencil beams. An ion beam monitor served as the initial development platform for this work and was tested in low energy heavy-ion beams ( 86 Kr +26 and protons). A prototype FBSM was fabricated and then tested in various radiation beams that included FLASH level dose per pulse electron beams, and a hospital RT clinic with electron beams. Results: Results presented in this report include image quality, response linearity, radiation hardness, spatial resolution, and real-time data processing. Furthermore, the HM scintillator was found to be highly radiation damage resistant. It exhibited a small 0.025%/kGy signal decrease from a 216 kGy cumulative dose resulting from continuous exposure for 15 min at a FLASH compatible dose rate of 237 Gy/s. Measurements of the signal amplitude versus beam fluence demonstrate linear response of the FBSM at FLASH compatible dose rates of >40 Gy/s. Comparison with commercial Gafchromic film indicates that the FBSM produces a high resolution 2D beam image and can reproduce a nearly identical beam profile, including primary beam tails. The spatial resolution was measured at 35–40 µm. Tests of the firmware beta version show successful operation at 20 000 Hz frame rate or 50 µs/frame, where the real-time analysis of the beam parameters is achieved in less than 1 µs. Conclusions: The FBSM is designed to provide real-time beam profile monitoring over a large active area without significantly degrading the beam quality. A prototype device has been staged in particle beams at currents of single particles up to FLASH level dose rates, using both continuous ion beams and pulsed electron beams. Using a novel scintillator, beam profiling has been demonstrated for currents extending from single particles to 10 nA currents. Radiation damage is minimal and even under FLASH conditions would require ≥50 kGy of accumulated exposure in a single spot to result in a 1% decrease in signal output. Beam imaging is comparable to radiochromic films, and provides immediate images without hours of processing. Real-time data processing, taking less than 50 µs (combined data transfer and analysis times), has been implemented in firmware for 20 kHz frame rates for continuous proton beams.

2D beam imaging↗
DOE OSTI2025

A simple introduction to the SiMPL method for density-based topology optimization

We introduce a novel method for solving density-based topology optimization problems: Sigmoidal Mirror descent with a Projected Latent variable (SiMPL). The SiMPL method (pronounced as “the simple method”) optimizes a design using only first-order derivative information of the objective function. The bound constraints on the density field are enforced with the help of the (negative) Fermi–Dirac entropy, which is also used to define a non-symmetric distance function called a Bregman divergence on the set of admissible designs. This Bregman divergence leads to a simple update rule that is further simplified with the help of a so-called latent variable. Because the SiMPL method involves discretizing the latent variable, it produces a sequence of pointwise-feasible iterates, even when high-order finite elements are used in the discretization. Numerical experiments demonstrate that the method outperforms other popular first-order optimization algorithms. In conclusion, to outline the general applicability of the technique, we include examples with (self-load) compliance minimization and compliant mechanism optimization problems.

Calculus of Variations and Optimization↗
DOE OSTI2023

Scalable in situ non-destructive evaluation of additively manufactured components using process monitoring, sensor fusion, and machine learning

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. However, the current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques, which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. In this work, an in situ NDE (INDE) system was engineered to detect subsurface flaws detected in X-Ray Computed Tomography (XCT) directly from process monitoring data. A multilayer, multimodal data input allowed the INDE system to detect numerous subsurface flaws in the size range of 200–1000µm using a novel human-in-the-loop annotation procedure. Furthermore, a framework was established for generating probability-of-detection (POD) and probability-of-false-alarm (PFA) curves compliant with NDE standards by systematically comparing instances of detected subsurface flaws to post-build XCT data. Here, we also introduce for the first time in the AM in situ sensing literature the a 90/95 – the flaw size corresponding to a 90% detection rate on the lower 95% confidence interval of the POD curve. The INDE system successfully demonstrated POD capabilities commensurate with traditional NDE methods. Traditional ML performance metrics were also shown to be inadequate for assessing the ability of the INDE system’s flaw detection performance. It is the hope of the authors that future studies will adopt the POD and PFA approach outlined here to provide better insight into the utility of process monitoring for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Energy efficiency and thermal resilience analysis for row houses using representative building energy models

Row houses, a prevalent medium-density urban archetype, were popularized during industrial era to accommodate the working class in the U.S. cities. Today, many of these structures are deteriorating, exacerbating the energy cost for residents with limited economic resources. Moreover, many households that lack Air Conditioning (AC) are vulnerable to extreme summer heat, an issue expected to worsen in the future. Energy-efficient retrofits can help mitigate these challenges. However, current literature provides limited insight into how existing building energy codes impact the energy efficiency and thermal resilience of row houses in current and future weather scenarios. This study provides a detailed method to address this gap by employing calibrated representative energy models of row houses as a baseline, and evaluating the annual energy savings and summertime thermal safety improvements from code compliant retrofits under current and future typical weather conditions. Using Baltimore City as a case study, results show that under current weather, retrofitting row houses yields significant energy savings along with notable thermal resilience improvements. The end unit row house realizes higher energy savings, whereas the interior unit experiences greater thermal resilience improvement after retrofitting. In future, retrofitted row houses can still save energy, but residents will face numerous hours of fatal indoor temperatures without AC in summer. Additionally, findings reveal stark zone-wise variations in thermal safety, and elevated humidity risks in certain zones post-retrofit, emphasizing the need for zonal retrofit strategies and better natural ventilation strategies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Considering computational speed vs. accuracy: Choosing appropriate mesoscale RVE boundary conditions

Modeling a material’s microstructure using continuum theories allows for inspection of the relationship between coarse scale and fine scale behaviors. Computational limits generally require selection of a sub-volume from a bulk sample in order to directly model the microstructure. Boundary conditions are applied to the sub-volume to mimic the excluded bulk material. Appropriate selection of boundary conditions helps effectively determine the appropriate spatial scale required of the sub-volume. Applicable boundary conditions include direct displacement, periodic, and uniform traction. While direct displacement and periodic boundary conditions are commonly used, uniform traction boundary conditions have seen limited use due to rigid body stability issues in simulations of compression or shear deformation. A new application of uniform traction boundary conditions was developed through linear constraint equations, similar to approaches employed by direct displacement and periodic boundary conditions, to quench rigid body motions with minimal interference of the relative deformation of the model. These boundary conditions were tested by compressing several synthetically generated periodic microstructures using the finite element method. Evaluating the effective stiffness along the compression axis, the direct displacement boundary condition produced the stiffest response, whereas the uniform traction boundary condition produced the most compliant. Periodic boundary conditions produced the same response for all volumes analyzed and both the direct displacement and uniform traction boundary conditions trended toward the periodic response as the domain volume increased. Computational performance was also evaluated for each boundary condition using implicit and explicit solvers. Direct displacement boundary conditions presented the lowest computational cost of all of the boundary conditions followed by periodic then uniform traction. The computational expense of periodic and uniform traction boundary conditions limited the viable spatial scale and mesh resolutions able to be simulated. Selection of appropriate boundary conditions for specific uses need to be a balance between allowable computational expense and accuracy of the method. Techniques for evaluating which boundary conditions to use are discussed.

42 ENGINEERING↗
DOE OSTI2022

Evaluation and beneficiation of high sulfur and high alkali fly ashes for use as supplementary cementitious materials in concrete

Coal-fuel power plants with semi-dry or dry flue gas desulfurization (FGD) systems produce high sulfur and/or high alkali fly ashes due to comingling of fly ash with FGD products. Such fly ashes do not meet the SO 3 content limit (5.0% max.) of ASTM C618 or are unable to mitigate the alkali-silica reaction. The mineralogy of the sulfur present in these ashes can vary significantly (e.g., CaSO 4 , CaSO 3 , Na2SO 4 ) based on the FGD technology used and this affects the performance of these fly ashes in concrete. Thus, the single SO 3 % limit of ASTM C618 is unable to capture the complexity and performance of fly ash, and this results in elimination of potentially viable pozzolans for concrete. Here this study performs a systematic investigation of the effect of SO 3 type and content in fly ash on various performance parameters of cement-fly ash pastes and mortars, including workability (flow and flow retention), pore fluid pH, setting time, strength development, and potential for deleterious expansion. To better quantify and understand these effects, the study considers both real and doped fly ashes (i.e., a blend of specification-compliant fly ash with target sulfur compounds). The poor performance observed in the case of setting time and pore fluid pH was successfully mitigated using chemical admixtures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High-performance windows improve thermal survivability of occupants during cold snaps

Exposure to low indoor air temperature is a major contributor to temperature-related mortality during extreme cold events, especially when power outages disrupt operation of space heating systems. This study explores the impact of high-performance windows on the thermal resilience of residential buildings during extreme cold weather and grid power outages, as well as their long-term benefits through energy efficiency and reduced risk of property damage. Building performance simulations were conducted for reference residential buildings in three construction vintages and two major U.S. cities located in cold climate zones, considering two types of extreme cold events: short and severe, and long and milder. Our research found that even houses compliant with current energy codes struggle to maintain safe indoor temperatures for more than a few hours during power outages, necessitating rapid evacuations. High-performance windows can extend the thermal survivability time by up to 3.8 days within a 7-day cold snap and significantly reduce risk of bursting frozen water pipes, depending on the building’s insulation and infiltration level, cold event severity, and occupant vulnerability. This extended thermal safety time is crucial in scenarios where reduced mobility complicates emergency responses in senior housing. In addition to boosting thermal resilience, upgrading older homes with high-performance windows can reduce heating energy consumption by over 18% and cooling energy by 15%. Our findings highlight the need to incorporate thermal resilience assessments into new designs or major retrofits, including the use of typical and extreme weather scenarios and advanced technologies like high-performance windows.

Krelling, Amanda F↗
DOE OSTI2024

Energy performance evaluation of the ASHRAE Guideline 36 control and reinforcement learning–based control using field measurements

This study evaluates the energy performance of ASHRAE Guideline 36–compliant control (ASHRAE 36 control) and reinforcement learning (RL)–based control through experimental field tests and a simulation study. Three field tests were conducted at Oak Ridge National Laboratory’s commercial building test facility in Oak Ridge, Tennessee: a baseline with a baseline conventional control, a test with ASHRAE 36 control, and a test with RL-based control. The selected ASHRAE 36 controls were trim and respond control, as well as variable air volume (VAV) box control. We compared the measured supply air temperature of the rooftop unit, VAV box supply air temperature, and VAV box supply airflow rate across the three test cases. The field data indicated that ASHRAE 36 controls operated as specified by ASHRAE Guideline 36. Based on these data, ASHRAE 36 control achieved a 45 % reduction in hourly averaged HVAC energy consumption compared with the baseline, and RL-based control achieved a 66 % reduction. These potential annual energy savings were confirmed using a calibrated whole-building energy model. Compared with the baseline, ASHRAE 36 control reduced HVAC energy consumption by 42 %, and RL-based control achieved a 54 % reduction. Furthermore, RL-based control reduced total HVAC energy consumption by 21 % more than ASHRAE 36 control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

An optimization framework for the network design of advanced district thermal energy systems

In this work, a topology optimization framework for district thermal energy systems is presented. The framework seeks to address the questions, for a given district, "What is the best subset of buildings to connect to a district thermal energy system, and by what network should they be connected, to minimize life cycle cost?" A particle swarm optimization approach is validated to address the selection of the subset of buildings, and a graph theory-based heuristic is validated for selection of the network topology for any candidate subset of buildings. The framework is applied to a prototypical urban district for illustrative purposes. Additionally, modeling of prototypical districts revealed reductions in source energy use intensity for heating and cooling of 21-25% through the use of advanced district energy systems relative to code-compliant, building level systems. The framework identifies solutions with life cycle cost values 14% to 72% lower than that of base case scenarios based on conventional design approaches, depending on the base case scenario selected. Analysis of the search space indicates that topology optimization facilitates reductions in life cycle cost, source energy use intensity, and carbon emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

New developments and verification of fusion blanket simulation capabilities in the MOOSE framework

Multiphysics modeling capabilities have a crucial role to play in the accelerated deployment of fusion energy. To that end, we developed new multiphysics fusion blanket simulation capabilities in the Multiphysics Object-Oriented Simulation Environment (MOOSE). Firstly, we expanded on the existing capabilities of the previously published work, by coupling 3D tritium transport modeling capabilities using the Tritium Migration Analysis Program, version 8 (TMAP8) to an existing tool including thermal hydraulics, fully three-dimensional (3D) heat transfer, and loosely coupled neutronics analysis. Secondly, we performed a thorough verification of the new capabilities and increased testing code coverage to meet MOOSE’s software quality standards. The MOOSE framework follows a strict software quality assurance plan to be Nuclear Quality Assurance, Level 1 compliant. The new multiphysics fusion blanket simulation capabilities are now held to the same standard. Thirdly, to demonstrate MOOSE’s new fusion blanket modeling capabilities, we performed a fully integrated, multiphysics simulation of a 3D solid ceramic breeder blanket design. This proof-of-concept simulation provides the temperature and tritium distribution across the blanket. In conclusion, the combined efforts towards software quality and the development of multiphysics coupling capabilities provide an effective and reliable framework for modeling solid ceramic fusion blankets using MOOSE.

modeling and simulation↗
DOE OSTI2020

Coating adhesion of a chromate-containing epoxy primer on Al2024-T3 surface processed by laser-interference

In this work, the coating adhesion test results are presented for a primer that was coated on laser-interference structured surfaces of as-received Al2024-T3 specimens, i.e., without employing any polishing, cleaning, or any other surface alteration techniques. All of the laser-interference processing was performed by splitting the primary beam of a Q-switched Nd:YAG pulsed nanosecond laser into two beams and focused them to the same spot. The specimens were spray painted with a chromate-containing epoxy primer, CA7233, compliant to MIL-PRF-23377 Type I Class C2 specification. The adhesion of primer on Al surface with different treatments was assessed using the ASTM D3359 X-cut and cross-hatch tests. It was found that the laser processed specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking for coating adhesion specimens than those prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. The rastering with either 4 mm/s or 6 mm/s with a laser fluence of 1.78 J/cm2 is recommended to attain acceptable coating adhesion, even higher than that with the anodizing surface treatment.These results indicate that laser-interference shows significant potential as a non-chemical surface preparation technique for these coatings.

36 MATERIALS SCIENCE↗