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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

RandONets: Shallow networks with random projections for learning linear and nonlinear operators

Deep neural networks have been extensively used for the solution of both the forward and the inverse problem for dynamical systems. However, their implementation necessitates optimizing a high-dimensional space of parameters and hyperparameters. This fact, along with the requirement of substantial computational resources, pose a barrier to achieving high numerical accuracy, but also interpretability. Here, to address the above challenges, we present Random Projection-based Operator Networks (RandONets): shallow networks with random projections and tailor-made numerical analysis methods that learn accurately and fast linear and nonlinear operators. Building on previous works, we prove that RandOnets are universal approximators of linear and nonlinear operators. Due to their simplicity, RandONets provide a one-step transformation of the input space, facilitating interpretability. For the evaluation of their performance, we focus on operators of PDEs. We show, that RandONets outperform by several orders of magnitude, both in terms of numerical approximation accuracy and computational cost, the “vanilla” DeepONets. Hence, we believe that our method will trigger further developments in the field of scientific machine learning, for the development of new ‘’light”schemes that will provide high accuracy while reducing dramatically the computational cost. A MATLAB toolbox for RandONets, including demos, is available on GitHub at https://github.com/GianlucaFabiani/RandONets.

Interpretable machine learning↗
NASA NTRS1976

Automated optimization techniques for aircraft synthesis

Application of numerical optimization techniques to automated conceptual aircraft design is examined. These methods are shown to be a general and efficient way to obtain quantitative information for evaluating alternative new vehicle projects. Fully automated design is compared with traditional point design methods and time and resource requirements for automated design are given. The NASA Ames Research Center aircraft synthesis program (ACSYNT) is described with special attention to calculation of the weight of a vehicle to fly a specified mission. The ACSYNT procedures for automatically obtaining sensitivity of the design (aircraft weight, performance and cost) to various vehicle, mission, and material technology parameters are presented. Examples are used to demonstrate the efficient application of these techniques.

Vanderplaats, G. N.↗
DOE OSTI2020

Investigating Scientific Data Change with User Research Methods

Scientific datasets are continually expanding and changing due to fluctuations with instruments, quality assessment and quality control processes, and modifications to software pipelines. Datasets include minimal information about these changes or their effects requiring scientists manually assess modifications through a number of labor intensive and ad-hoc steps. The Deduce project is investigating data change to develop metrics, methods, and tools that will help scientists systematically identify and make decisions around data changes. Currently, there is a lack of understanding, and common practices, for identifying and evaluating changes in datasets since systematically measuring and managing data change is under explored in scientific work. We are conducting user research to address this need by exploring scientist's conceptualizations, behaviors, needs, and motivations when dealing with changing datasets. Our user research utilizes multiple methods to produce foundational, generative insights and evaluate research products produced by our team. In this paper, we detail our user research process and outline our findings about data change that emerge from our studies. Our work illustrates how scientific software teams can push beyond just usability testing user interfaces or tools to better probe the underlying ideas they are developing solutions to address.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2024

Optimization and Evaluation of Energy Savings for Connected and Autonomous Off-Road Vehicles

Off-road vehicles, such as wheel loaders, excavators, and harvesters, are extensively utilized across a wide range of industries, including construction, agriculture, and mining. These machines have become indispensable in supporting the day-to-day operational needs of a nation, playing a critical role in various sectors' infrastructure and productivity. However, despite their utility, off-road vehicles are significant consumers of fossil fuels, resulting in substantial emissions that contribute to environmental degradation. This highlights the pressing need for research and technological advancements aimed at improving their energy efficiency and reducing their carbon footprint. There are, however, two primary challenges that must be addressed to achieve these goals. First, off-road vehicles typically perform both driving and working tasks simultaneously, which introduces a high level of complexity into their overall dynamic systems. Analysis the interactions between these functions is challenging. Second, research into off-road vehicles is inherently interdisciplinary, demanding expertise across several domains such as fluid power systems, vehicle dynamics, control theory, optimization techniques, and real-world implementation. Recognizing these challenges, we proposed the project titled "Optimization and Evaluation of Energy Savings for Connected and Autonomous Off-Road Vehicles" as a comprehensive solution to enhance fuel efficiency while simultaneously improving productivity. This project specifically focuses on autonomous off-road vehicles, with particular attention to wheel loaders, and seeks to develop novel methods to optimize energy consumption without sacrificing operational performance. The project integrates real-time control algorithms, vehicle dynamics modeling, and co-optimization of powertrain system and vehicle system to achieve these goals. Our optimization strategy dynamically co-optimizes critical parameters at both the powertrain and vehicle levels, including vehicle speed, working tool movements, powertrain dynamics, and engine operations in real-time. To streamline this optimization process, we developed a vehicle model that captures the key dynamics while significantly enhancing computational efficiency. This allows the system to intelligently minimize fuel consumption, all while maintaining or even improving productivity through real-time calculations during various off-road operations. To validate the effectiveness of this energy optimization method, we introduced a state-of-the-art Hardware-in-the-Loop (HIL) testbed. This reconfigurable testbed seamlessly integrates the actual engine with virtual models of the wheel loader's subsystems, allowing for accurate emulation of real-world operational loads and environments. By simulating these conditions, the HIL testbed enables us to evaluate the wheel loader’s performance under diverse working scenarios, ensuring the developed solution is applicable in real-world operations. This testbed proved to be instrumental in validating the optimization algorithms and demonstrating the system's practical effectiveness. During the evaluation and testing phase, we employed the HIL testbed to rigorously assess the energy savings and productivity improvements generated by the optimized system. The results were highly encouraging, revealing that the automated wheel loader achieved over 30% fuel savings compared to traditional, human-operated cycles, with comparable or even enhanced levels of productivity. The insights gained from this HIL-based testing provided critical validation of our approach and highlighted the potential for deploying these optimized autonomous technologies in real-world off-road vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗
DOE OSTI2025

High Performance (R-10/inch) Clay-Cellulose-Silica Nanopore Insulation Board For New and Retrofit Buildings (Final Scientific Report)

The objective of Liatris’s 3-year DOE BENEFIT project was to develop and validate a high-performance, lightweight, aerogel-based insulation board of ≥R-10/inch at a cost of ≤$\$$1.50 per board foot using non-flammable inorganic nanocomposites. We have summarized each yearly goal below: Year 1 – Ambient dried inorganic/organic nanocomposite, R-6/inch Year 2 – Processing efficiency and cost down, R-8/inch at $\$$2.0/board-ft Year 3 – Scale up to continuous, pilot production of R-10 at ≤ $\$$1.50/board-ft Over the course of the project period, Liatris has successfully met or exceeded all of the goals outlined above. The project scope over 3 years was extensive, covering method development of ambient dried silica aerogels in Budget Period 1, process formulation and R-value improvement in Budget Period 2, and composite scale up with corporate partners in Budget Period 3. Over the course of the project Liatris has been able to progressively improve the thermal resistance properties from about R-6/in to > R-11/in, 2-3X the performance of conventional insulation products.

36 MATERIALS SCIENCE↗
NASA NTRS1998

3D-Stereoscopic Analysis of Solar Active Region Loops: I: SoHo/EIT Observations at Temperatures of 1.0-1.5 MK

The three-dimensional (3D) structure of solar active region NOAA 7986 observed on 1996 August 30 with the Extrem-ultraviolet Imaging Telescope (EIT) onboard the Solar and Heliospheric Observatory (SoHO) is analyzed. We develop a new method of Dynamic Stereoscopy to reconstruct the 3D geometry of dynamically changing loops, which allows us to determine the orientation of the loop plane with respect to the line-of-sight, a prerequisite to correct properly for projection effects in 3D loop models. With this method and the filter-ratio technique applied to EIT 171 A and 195 A images we determine the 3D coordinates (x(s), y(s), z(s)), the loop width) w(s), the electron density n(sub e)(s), and the electron temperature T(sub e)(s) as function of the loop length s for 30 loop segments. Fitting the loop densities with an exponential density model n(sub e)(h) we find that the so inferred scale height temperatures, T(sub e)(sup lambda) = 1.22 +/- 0.23 MK, match closely the EIT filter-ratio temperatures, T(sub e)(sup FIT) = 1.21 +/- 0.06 MK. We conclude that these rather large-scale loops (with heights of h approx. equals 50 - 200 Mm) that dominate EIT 171 A images are close to thermal equilibrium. Most of the loops show no significant thickness variation w(s), but many exhibit a trend of increasing temperature (dT/ds greater than 0) above the footpoint.

Aschwanden, Markus J.↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
NASA NTRS2010

Project M: Scale Model of Lunar Landing Site of Apollo 17

The basis of the project was creating a scale model representation of the Apollo 17 lunar landing site. Vital components included surface slope characteristics, crater sizes and locations, prominent rocks, and lighting conditions. The model was made for Project M support when evaluating approach and terminal descent as well as when planning surface operations with respect to the terrain. The project had five main mi lestones during the length of the project. The first was examining the best method to use to re-create the Apollo 17 landing site and then reviewing research fmdings with Dr. Tim Crain and EO staff which occurred on June 25, 2010 at a meeting. The second step was formulating a construction plan, budget, and schedule and then presenting the plan for authority to proceed which occurred on July 6,2010. The third part was building a prototype to test materials and building processes which were completed by July 13, 2010. Next was assembling the landing site model and presenting a mid-term construction status report on July 29, 2010. The fifth and final milestone was demonstrating the model and presenting an exit pitch which happened on August 4, 2010. The project was very technical: it needed a lot of research about moon topography, lighting conditions and angles of the sun on the moon, Apollo 17, and Autonomous Landing and Hazard Avoidance Technology (ALHAT), before starting the actual building process. This required using Spreadsheets, searching internet sources and conducting personal meetings with project representatives. This information assisted the interns in deciding the scale of the model with respect to cracks, craters and rocks and their relative sizes as the objects mentioned could interfere with any of the Lunar Landers: Apollo, Project M and future Landers. The project concluded with the completion of a three dimensional scale model of the Apollo 17 Lunar landing site. This model assists Project M members because they can now visualize approach phase, terminal descent phase, and surface phase operations on the physical model. The project had an additional requirement that was also satisfied: the granite table the model was placed on must be returnable to its original condition if needed in the future.

O'Brien, Hollie↗
DOE OSTI2020

Acciona Power Plant Hydrogen Mitigation Project

In 2014, Acciona Solar Power and the National Renewable Energy Laboratory initiated discussions to identify a method to solve a long-standing efficiency loss problem at parabolic trough power plants. Parabolic trough power plants begin to show lost thermal efficiency after six years of operation, due to the presence of trace concentrations of hydrogen in the heat transfer fluid that circulates in the power plant. Trace levels of hydrogen infiltrate the collector field receivers, increasing their heat loss, and decreasing the power plants’ thermal efficiency. At the time, Acciona’s Nevada Solar One power plant in Boulder City, Nevada was starting to show this efficiency loss. After several discussions, APS and NREL agreed to a collaborative effort (CRADA) to develop and implement a method to reduce hydrogen levels in the circulating HTF at the NSO power plant. The project was planned as a three-year effort, and work started in June 2015. The CRADA’s goal was to solve the long-standing lost efficiency problem caused by the buildup of hydrogen in the HTF, which significantly impacts the efficiency, electricity generation, and revenue from parabolic trough power plants.

08 HYDROGEN↗
DOE OSTI2024

Non-conformity Scores for High-Quality Uncertainty Quantification from Conformal Prediction

High-quality uncertainty quantification (UQ) is a critical component of enabling trust in deep learning (DL) models and is especially important if DL models are to be deployed in high-consequence applications. Conformal prediction (CP) methods represent an emerging nonparametric approach for producing UQ that is easily interpretable and, under weak assumptions, provides a guarantee regarding UQ quality. This report describes the research outputs of an Exploratory Express Laboratory Directed Research and Development (LDRD) project at Sandia National Laboratories. This project focused on how best to implement CP methods for DL models. This report introduces new methodology for obtaining high-quality UQ from DL models using CP methods, describes a novel system of assessing UQ quality, and provides experimental results that demonstrate the quality of the new methodology and utility of the UQ quality assessment system. Avenues for future research and discussion of potential impacts at Sandia and in the wider research community are also given.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Fabrication of Low-Cost Large-Volume Ceramic A 2 HfX 6 (A= Cs or Tl, X = Cl, Br, or I) Scintillators for Gamma Ray Detection (SBIR Phase I Final Technical Report)

Scintillator crystals play an important role in the radiation detection field. Widespread use of scintillators as gamma-ray detectors is largely generated by their extensive availability and tunable properties, such high light output, high stopping power (Z eff ), fast decay time, and good proportionality. Additionally, the cost for manufacturing a scintillation detector like NaI:Tl is usually considerably lower than the cost for manufacturing a semiconductor detector like CdZnTe. Because there is no such thing as an ideal scintillation material, an application requiring certain detection characteristics may incorporate a scintillator tailored to its specific properties. The vast variety of applications and requirements necessitates more research into new scintillation materials and/or better methods of producing existing materials.The goal of this project was to grow low cost and environmentally stable inorganic transparent ceramic scintillators with excellent gamma ray resolution, excellent energy proportionality, excellent detection efficiency due to high density (>5 g/cm 3 ) and very high Z eff (55-80), and good light yields (>40,000 ph/MeV). In Phase I Xtallized Intelligence, Inc. (XI, Inc) developed a novel ceramic fabrication technique to produce low cost and environmentally stable highly efficient inorganic transparent ceramic scintillators of various dimensions. XI, Inc., collaborating with Fisk University (Fisk), investigated the scintillation properties of these new ceramic scintillators and compared them to in their single crystal counterparts. The results of this Phase I project show that successful production of high-quality inorganic halide ceramic scintillators Cs 2 HfCl 6 (CHC) and Tl 2 HfCl 6 (THC). Both ceramic CHC and THC scintillators have achieved good performance close to the performance of their single crystal counterparts. Fabricating these inorganic ceramic scintillators mitigate many issues encountered during conventional bulk crystal growth by melt methods. Additional benefits of the ceramic fabrication technique include high production yield, low production cost, fast production time, and no material waste Inorganic transparent ceramic scintillators produced in this project will enhance cost effectiveness at the instrument level based on low projected cost of the proposed compounds, as much smaller crystal sizes would be required to achieve similar efficiency as current radioisotope identification devices (RIID’s) used in homeland security applications as well as spectrometers in high energy physics applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Charged Wellbore Casing Controlled Source Electromagnetics (CWC-CSEM) for Reservoir Imaging and Monitoring (Final report)

This project addresses the needs of the U.S. Department of Energy (DOE) to develop advanced monitoring technologies and protocols to track the fate of subsurface carbon dioxide (CO2) plumes for carbon storage. Specifically, the project seeks to develop and test a unique and novel system of technologies consisting of electromagnetic data acquisition, coupled multiphysics imaging, and reservoir model enhancement to understand the migration and long-term distribution of CO2 in the subsurface. The overarching objective is to develop an integrated approach for long term monitoring of carbon storage. The two main components of the project include the methodology development and the test of the method at a field site. The methodology component consists of 1) developing the field procedure and protocol for collecting time-lapse controlled-source electromagnetic (CSEM) data with source electric current injected into the subsurface through wellbore casings; 2) building of background 3D electrical conductivity utilizing multiple sources of data such as supplemental surface transient EM (TEM) surveys, well-logs, and seismic structural information, for enhancing CSEM signal from reservoir depths; and 3) coupled multiphysics simulations and inversion of CSEM data constrained by production data and by structural information from seismic imaging of the reservoir and overlying formations. The testing component used the field site of Bell Creek Oil Field, which served both as a field laboratory for the method development as well as a test site to evaluate the CSEM signal strengths and the methodology developed in this research project. We have accomplished all the proposed tasks and developed the methodology as planned. These include the procedure for time-lapse CSEM data acquisition, data processing techniques, integration with 3D conductivity model building, fast reservoir simulation for history matching using machine learning, and interpreting CSEM data with coupling to the reservoir modeling. Collectively, the outcome of these tasks form a coherent workflow that can be applied to monitor dedicated carbon storage in saline reservoirs. The testing component evaluated the applicability and limitations of the method, and concluded that the method would be ideal for monitoring dedicated carbon storage sites utilizing saline reservoirs.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1996

The Mars Surveyor Operations Project Command Generation Process

The Mars Global Surveyor mission (MGS) will be the first in a series of Mars missions to recover the science lost when the ill fated Mars Observer spacecraft suffered a catastrophic anomaly in its propulsion system and was unable to attain orbital capture at the planet...This paper will describe in detail the methods employed by the MSOP ( Mars Surveyor Operations Project)flight team to accelerate the command generation process.

MGS↗
DOE OSTI2024

Applications of Fuzzy Logic for Tritium Sensing Technology

Fuzzy Logic is a mathematical method that can represent human-like decisions by analyzing vagueness. The project is a practical approach for evaluating sensors using a fuzzy group best-worst method. Results What is the best sensor? The fuzzy logic methods give an answer to that through a selection system. The relationship between the inputs and the outputs gives consumers an understanding of how the best sensor was found through a scoring of each quality/criteria and their corresponding sub-criteria through expert opinion.

Holman, Allyson↗
NASA NTRS2014

Sharepoint Team Site Configuration

The Data Mining project seeks to bring the capability of data visualization to NASA anomaly and problem reporting systems for the purpose of improving data trending, evaluations, and analyses. Currently NASA systems are tailored to meet the specific needs of its organizations. This tailoring has led to a variety of nomenclatures and levels of annotation for procedures, parts and anomalies making difficult the realization of the common causes for anomalies. Making significant observations and realizing the connection between these causes without a common way to view data is difficult to impossible. The Data Mining project is in its early stages of presenting a common visualization of normalized data through a web based portal. In this paper I detail what I have learned and what I have accomplished during my time as an intern toward the purpose of creating the project portal. I have gone through an iterative process of familiarization with the project and its goals, site design, research, modification and review on the road to creating a common method and location to view the visualized data created under this project.

iss↗
DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2003

Improved Crystal Quality by Detached Solidification in Microgravity

The goals of our work on detached solidification have been to: 1) Develop a complete understanding of all of the phenomena of detached solidification; 2) Make it possible to achieve detached solidification reproducibly; and 3) Increase crystallographic perfection through detached solidification. Specifically, we aimed in this project to: 1) Identify a system and develop methods that would allow viewing of the melt surface and convection in the melt during detached solidification in microgravity; 2) Improve understanding of the origination and evolution of detachment through experiments and theoretical treatments; and 3) Achieve detachment on earth. The project resulted in 14 publications, 15 presentations, completion of 2 Ph.D. theses, and completion of 2 M.S. theses. Two additional papers are currently being reviewed for publication. Copies of most of the papers are included as appendices.

Regel, Liya L.↗