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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 1,315 records · Page 73
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Manufacturing for Design: A Conceptual Overview

Efforts aimed at improving “production readiness” seek to ensure that the transition from design to production is as smooth as possible and that adequate planning has taken place to allow for efficient and productive operation. A key component of this process is encouraging a “Design for Manufacturing” approach in which design engineers constrain their designs with general and specific manufacturability limitations in mind. This approach can reduce the design/redesign cycle, improving efficiency.

42 ENGINEERING↗
DOE OSTI2026

Bridging Cloud and Edge Computing at NREL Using CONNECT: Cloud Optimized Networking for Next-Gen Edge Computing Technologies [Slides]

CONNECT is an innovative on-premise hardware and software solution that integrates edge and cloud computing infrastructure at NREL. Built on the AWS Greengrass middleware and leveraging the MQTT protocol, CONNECT enables real-time data streaming from IoT devices and gateways to both cloud and local services, empowering researchers to rapidly capture, analyze, and act upon edge-generated data while leveraging cloud capabilities. The platform addresses research infrastructure challenges by providing a pre-approved platform which is already configured with the correct networking and cybersecurity baselines thus eliminating procurement delays and enabling on-demand availability. CONNECT's hybrid architecture efficiently manages burstable workloads, allowing research teams to dynamically scale computational capacity, handle peak data loads, and reduce operational bottlenecks. Advanced capabilities include built-in GPU support for executing machine learning models which enables low-latency inference at the edge from models trained in the cloud. This architecture supports real-time analytics and filtering, providing a mechanism to allow only transmitting and processing high-value data. Cloud-based configuration management permits engineers to manage on-premise systems remotely, optimizing operational efficiency. By bridging edge and cloud computing, CONNECT provides NREL researchers with a flexible, scalable platform that accelerates scientific discovery while maintaining robust security and performance standards.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

FORGE: Summer Internship Experience

The presentation summarizes my summer internship experience with the Fluids Group at Fermilab. During the internship, I learned about the maintenance and operation of water pumps and other equipment that support important facility systems. I worked alongside fluids technicians and gained hands-on experience with maintaining machinery, installing pipes, refilling water, cleaning RF cavities, and observing new water-pump construction for PIP-II. My projects included repairing an air dryer, learning how heat exchangers cool low-conductivity water, and cleaning the copper cooling rings used in RF cavities. Overall, this experience helped me better understand the work processes of technicians and the importance of practical technical knowledge for engineers.

Uribe, Anthony [Unlisted, US, IL]↗
DOE OSTI2020

Lagrangian simulations of spray interaction with a surface using a stochastic multi-regime impingement model

Modeling of spray impingement upon the piston or cylinder surface is important for hydrocarbon emission and soot predictions in high-fidelity simulation of internal combustion engines with direct injections. Due to the complexity of the physical process of spray impingement, current computational models heavily rely on the empirical studies which involve large uncertainties. A computational model is presented for spray impingement on solid walls in general computational fluid dynamics (CFD) simulations. The model adopts the Marmanis-Thoroddsen theory for determining the number of secondary droplets and a stochastic method for calculating the velocities of the secondary droplets. The numerical methods and parallel implementation of the impingement model are presented in detail. The model is implemented in Grit, which is a recently developed CPU/GPU performance-portable Lagrangian particle library, for accelerating spray simulations. The model and its implementation are tested for examples of spray impingements on flat and smooth surfaces with different impingement angles.

Ge, Wenjun↗
DOE OSTI2021

An automated approach to the alignment of compound refractive lenses

Compound refractive lenses (CRLs) are established X-ray focusing optics, and are thus a key element of many beamlines at X-ray facilities, used to either to focus a beam or image a sample. While CRLs are quite established, the stack of single lens elements affords a very small numerical aperture because of the thick lens profile, making them far more difficult to align than classical optical lenses that obey the thin-lens approximation. This means that the alignment must be very precise and is highly sensitive to changes to the incident beam; aligning CRLs is thus typically treated as a time-consuming manual process. Many groups circumvent day-to-day realignment by using engineering controls (e.g. mounting optics) that sacrifice some of the beam’s focusing characteristics, i.e. spot size, or resolution. While these choices minimize setup time, there are clear disadvantages. This work presents a new automated approach to align CRLs using a simple alignment apparatus that is easy to adapt and install at different types of X-ray experiments or facilities. Our approach builds on recent CRL modeling efforts, using an approach based on the Stochastic Nelder-Mead (SNM) simplex method. We demonstrate the efficacy of this method by numerical simulation and then extend this test to real experiments conducted at the Advanced Photon Source to confirm its performance with a synchrotron X-ray beam. This work provides an opportunity to automate key instrumentation at X-ray facilities.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Resilient, Rural, and Revolutionary: Salisbury Square's Direct-Current Affordable Microgrid Community: Preprint

The technology to interconnect buildings with a dedicated direct-current (DC) power distribution network is in place today; what is missing is a turnkey approach to designing a DC microgrid - and the business models allowing such systems to be deployed, owned, and operated at scale. To close this gap, the Salisbury Square Development Team, comprising clean-energy experts, has engineered a resilient community DC microgrid for an affordable housing community in Randolph, Vermont. Ten single-family, occupant-owned residences and 12 multifamily rental units will share locally generated and stored solar energy via a DC power distribution bus capable of operating during extended grid outages. With a DC power distribution network in place, each home will be equipped with high-efficiency DC lighting and appliances, operating alongside alternating current (AC) appliances, even during an islanded mode of operation. To obtain a comprehensive understanding of what is possible and achievable, the Team collaborated with the local utility, regulatory agencies, a national laboratory, energy-as-service providers, and vendors. The collaborators evaluated microgrid typologies, business models, and energy modeling, and analyzed electrification and resilience. Further, the Team applied the URBANoptTM (Urban Renewable Building and Neighborhood optimization, NREL 2022) software development kit (SDK) to Salisbury Square's single-family and multifamily buildings to validate workflows and identify needs for advanced capability. This paper addresses the barriers to entry, scalability, and impact on residents and system ownership. It also examines the analysis that informed the design and engineering of the DC microgrid and the opportunities to streamline the process.

DER↗
DOE OSTI2025

Single-shot electrical detection of short-wavelength magnon pulse transmission in a magnonic thin-film waveguide

Abstract The advance of magnon spintronics requires understanding of time-domain magnon pulse transmission in order to develop high-speed information processing protocols. In this work, we demonstrate single-shot electrical detection of narrow-band magnon pulse transmission in a yttrium iron garnet thin-film delay line. The high signal-to-background ratio of magnon transmission band allows us to directly probe the magnon transmission electrically using a fast oscilloscope and to study its spectral evolution using Fast Fourier Transform (FFT) of the time-domain transmitted signal. At elevated input power, we show a magnon transmission reduction and a spectral distortion, which can be understood by the nonlinear magnon excitation in the transmission band defined by the antenna geometry. In addition, we also find that the higher- (lower-) frequency magnon spectral component exhibits a lower (higher) magnon group velocity, showing a dispersion agreeing with the Damon-Eshbach dependence. Our results provide important guidance of magnon pulse engineering for their applications in spin wave computing and coherent magnon information processing.

Song, Moojune↗
DOE OSTI2021

Determination of a most representative cycle from cylinder pressure ensembles via statistical method using distribution skewness

In internal combustion engine research, cylinder pressure measurements provide valuable information about the underlying thermodynamic and combustion processes, and are typically collected in ensembles of several 100 traces. Although in some particular fields of combustion research all traces are analyzed, in most cases only one trace is studied because analyzing all the traces is impractical due to the large number of collected samples. Instead, an ensemble-averaged pressure trace is commonly calculated and used for analysis. However, this pressure trace is highly smoothed and dynamic information is lost during the averaging process. With the average trace, pressure rise rates are lower and pressure oscillations such as the ones resulting from combustion knock are lost. In this work, a statistical method was developed to determine the “most representative cycle,” which is the cycle from the ensemble that has the pressure trace most representative of the engine operating condition. Eleven characteristic parameters are computed from each pressure trace and probabilistic distributions are obtained for each of the parameters using all the traces in the ensemble. Finally, the most representative cycle is selected by means of a cost function minimization. The benefits of this method are illustrated using experimental data from four very different engine platforms, under four different combustion modes and over a range of operating conditions.

42 ENGINEERING↗
DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Mitigation of chromosome loss in clinical CRISPR-Cas9-engineered T cells

CRISPR-Cas9 genome editing has enabled advanced T cell therapies, but occasional loss of the targeted chromosome remains a safety concern. To investigate whether Cas9-induced chromosome loss is a universal phenomenon and evaluate its clinical significance, we conducted a systematic analysis in primary human T cells. Arrayed and pooled CRISPR screens revealed that chromosome loss was generalizable across the genome and resulted in partial and entire loss of the targeted chromosome, including in preclinical chimeric antigen receptor T cells. T cells with chromosome loss persisted for weeks in culture, implying the potential to interfere with clinical use. A modified cell manufacturing process, employed in our first-in-human clinical trial of Cas9-engineered T cells (NCT03399448), reduced chromosome loss while largely preserving genome editing efficacy. Expression of p53 correlated with protection from chromosome loss observed in this protocol, suggesting both a mechanism and strategy for T cell engineering that mitigates this genotoxicity in the clinic.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

The objective is to develop continuous processing of carbon foam products made from coal at atmospheric pressure. Both carbon foam panels and lightweight carbon foam aggregates have been developed. A successful outcome would: 1) significantly reduce the cost to manufacture carbon foam through reductions in capital and labor costs, 2) significantly reduce the manufacturing time from weeks to hours, and 3) enable the manufacture of much larger volumes of carbon foam. All of these features are expected to enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Revisiting Theoretical Tools and Approaches for the Valorization of Recalcitrant Lignocellulosic Biomass to Value-Added Chemicals

Biorefinery processes for converting lignocellulosic biomass to fuels and chemicals proceed via an integrated series of steps. Biomass is first pretreated and deconstructed using chemical catalysts and/or enzymes to liberate sugar monomers and lignin fragments. Deconstruction is followed by a conversion step in which engineered host organisms assimilate the released sugar monomers and lignin fragments, and produce value-added fuels and chemicals. Over the past couple of decades, a significant amount of work has been done to develop innovative biomass deconstruction and conversion processes that efficiently solubilize biomass, separate lignin from the biomass, maximize yields of bioavailable sugars and lignin fragments and convert the majority of these carbon sources into fuels, commodity chemicals, and materials. Herein, we advocate that advanced in silico approaches provide a theoretical framework for developing efficient processes for lignocellulosic biomass valorization and maximizing yields of sugars and lignin fragments during deconstruction and fuel and chemical titers during conversion. This manuscript surveys the latest developments in lignocellulosic biomass valorization with special attention given to highlighting computational approaches used in process optimization for lignocellulose pretreatment; enzyme engineering for enhanced saccharification and delignification; and prediction of the genome modification necessary for desired pathway fine-tuning to upgrade products from biomass deconstruction into value-added products. Physics-based modeling approaches such as density functional theory calculations and molecular dynamics simulations have been most impactful in studies aimed at exploring the molecular level details of solvent-biomass interactions, reaction mechanisms occurring in biomass-solvent systems, and the catalytic mechanisms and engineering of enzymes involved in biomass degradation. More recently, with ever increasing amounts of data from, for example, advanced mutli-omics experiments, machine learning approaches have begun to make important contributions in synthetic biology and optimization of metabolic pathways for production of biofuels and chemicals.

09 BIOMASS FUELS↗
DOE OSTI2024

Approaches for the Simulation of Coupled Processes in Evolving Fractured Porous Media Enabled by Exascale Computing

Models have historically represented fractured porous media with continuum descriptions that characterize the media using bulk parameters. The impact of small-scale features is not captured in these models, although they may be controlling the performance of subsurface applications. Pore-scale models can simulate processes in small-scale features by representing the pore space geometry explicitly but are computationally expensive for large domains. The alternative multiscale approach entails the combination of pore-scale and continuum-scale descriptions in a single framework. We use Chombo-Crunch, a computational capability that discretizes complex geometries with an adaptive, embedded boundary method to contrast these two approaches. Chombo-Crunch takes advantage of recent computational performance and memory bandwidth improvements resulting from the emergence of exascale computing resources. These combined improvements enable the efficient simulation of reactive transport in fractured media with a high degree of fidelity and the ability to capture the control small-scale processes exert on the overall medium evolution.

42 ENGINEERING↗
DOE OSTI2023

Engineered Polymer Architectures for Thermo–Responsive Desiccants in Dehumidification Applications

Humidity control is relevant to many processes in buildings and manufacturing and is responsible for over 600 million tons of CO 2 annually. As such, desiccants that can efficiently remove moisture from air can greatly reduce emissions. A new class of desiccant materials, thermo–responsive desiccants, has been of increased interest in the literature. These materials are generally based on thermo–responsive polymers and exhibit a temperature–dependent isotherm, an attribute that is small in traditional desiccants. In this work, seven key parameters needed to create an effective thermo–responsive polymer desiccant are identified using a combination of modeling and experimental data. Further, it is found that more thermo–responsiveness is not necessarily better for energy efficiency, and that an optimal, “medium” value is desired. Additionally, polymer composition and architecture play key roles in adjusting the seven key parameters. Finally, based on findings from both modeling and experimental work, guidelines on synthesizing future thermo–responsive polymer desiccants are presented.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Robust optimization of flexible diafiltration systems for critical mineral separations

This paper provides major contributions in expanding the literature for membrane process design with critical mineral recovery applications and showcasing the importance of robust design techniques for reducing risks of underperformance in such systems. Here, a membrane process flowsheet featuring PrOMMiS membrane models for recovering lithium/cobalt from spent batteries is showcased, uncertainty in membrane sieving and localized fouling are considered, and robust designs are obtained using the PyROS toolset. This paper is intended for a general audience of researchers working in critical minerals, membranes, and optimization related areas.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Industrial Assessment Center

Established in 1990, San Diego State University’s (SDSU) Industrial Assessment Center (IAC) is proud of its years of service. During this period, it has served over 620 small and medium-sized manufacturing plants in Southern California. SDSU/IAC’s efforts to transfer state-of-the-art technologies to industry have increased revenues, cultivated creativity, improved energy efficiencies, and benefited the environment. The Center has contributed to the region's economic growth and stability by assisting small and medium size companies to better compete in the global market. It has helped mitigate climate change by reducing greenhouse gas emissions. IAC activities have fostered productive relationships between the University and local industry, assisted industrial sectors to improve their energy efficiency and enhance their manufacturing productivity, in turn impacting the material and working conditions of their employees. In addition to financial savings and environmental benefits, we have trained tens of students who became energy specialists in various companies. Thus, a substantial benefit of the IAC has been the ongoing training of engineering faculty and students. All IAC graduates were offered jobs before or within weeks of their graduation. The activities of the SDSU/IAC have expanded the institutional expertise of the College and improved the knowledge base of the faculties involved leading to several related publications, master’s theses, and senior student projects. Significant number of peer-reviewed publications of the IAC director at SDSU have greatly benefitted from the experience of the Center. As a result of this extensive exposure to manufacturing processes, the SDSU/IAC has grown to be an integral component of SDSU’s engineering research and training. We have successfully built upon these established achievements and academic excellence. IAC service to industry is particularly vital in Southern California, a region with one of the highest manufacturing concentrations in the country. SDSU/IAC has understood and implemented the overall objectives of DOE’s IAC program and guidelines except for the pandemic years when the country’s manufacturing sector was put in dire stress. In addition to student training and service to industry, IAC’s contribution to state and local governments as well as utility companies to assess energy policies and design rebate and incentive strategies cannot be undermined.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗