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At least 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Reviewing flexibility in industrial electrification: Focusing on green ammonia and steel in the United States

The renewable energy transition in the power sector involves a paradigm shift for flexibility. Flexible demand is more attainable than before, while supply flexibility faces new constraints due to the increased share of variable renewable resources. Increased demand flexibility can allow less use of peaking power plants and avoid need for additional capacity. Industrial flexibility could be especially interesting in this regard, as industrial customers are larger on average than other customers and have typically provided the largest share of demand response in the United States. We consider industrial demand, studying characteristics of flexible industrial loads. We then examine the dynamics of change occurring around industrial load flexibility by focusing on two case studies: green ammonia and steel production via electric arc furnaces. Electric arc furnace steel production is an important component of current demand response programs, whereas green ammonia and green fuels offer new paradigms for flexibility. We analyze the structure and functions of the technological innovation systems of load flexibility in those two industries via interviews with twenty-two stakeholders. Here, we conclude that in the United States these technological innovation systems are not well-functioning for industry in general or for steel, but do seem to be present for green ammonia. Additionally, explicit connections between scope two greenhouse gas emissions (those from purchased energy) and flexibility are lacking, and likewise industry stakeholders do not appear to make a connection between decarbonization and load flexibility, thus flexible demand is not viewed as a tool in industrial decarbonization.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Reviewing Flexibility in Industrial Electrification: U.S. Green Ammonia and Steel Industries [Slides]

The renewable energy transition in the power sector involves a paradigm shift for flexibility. Supply flexibility faces new constraints due to the increased share of variable renewable resources. Increased demand flexibility can allow less use of peaking power plants and delay need for additional capacity and transmission. Industrial customers are larger on average than residential and commercial consumers and have typically provided the largest share of demand response in the United States. We consider industrial demand, studying characteristics of flexible industrial loads. We examine the dynamics of change occurring around industrial load flexibility by focusing on two case studies: green ammonia and steel production via electric arc furnaces. Electric arc furnace steel production is an important component of current demand response programs, whereas green ammonia and green fuels offer new paradigms for flexibility. We analyze the structure and functions of the technological innovation systems of load flexibility in those two industries via interviews with twenty-two stakeholders. We conclude that the technological innovation systems are not well-functioning for flexibility in EAF based steelmaking, but are in the green ammonia space. Explicit connections between scope two greenhouse gas emissions reporting and flexibility are lacking, and industry stakeholders do not appear to make a connection between decarbonization and load flexibility.

25 ENERGY STORAGE↗
NASA NTRS1990

A unique high heat flux facility for testing hypersonic engine components

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding high thermal loads expected during hypersonic flights. Consequently, there is a need for experimental facilities capable of providing a high heat flux environment for testing compound concepts and verifying analyses. A hydrogen/oxygen rocket engine was developed to provide a high enthalpy/high heat flux environment for component evaluation. This Hot Gas Facility is capable of providing heat fluxes ranging from 200 (on flat surfaces) up to 8000 Btu per sq ft per sec (at a leading edge stagnation point). Gas temperatures up to 5500 R can be attained as well as Reynolds numbers up to 360,000 per ft. Test articles such as cowl leading edges, transpiration-cooled seals, fuel injectors, and cooled panel concepts can be evaluated with gaseous hydrogen as coolant. This facility and its configuration and test capabilities are discussed. Results from flow characterization experiments are also shown and their implications considered.

Melis, Matthew E.↗
DOE OSTI2024

Rotor Magnet Fault Analysis in Permanent Magnet AC Machines Under Load Conditions - All Electric Transportation Systems

This paper studies the performance of a Permanent Magnet (PM) alternating-current (AC) machine when subjected to faults under load conditions. The effect of varying load torques, and unbalances are found to be potential causes of rotor faults, inducing physical magnet defects or broken rotor-PMs. The consequent and immediate impact on the machine quantities is observed through anomalous change in torque-speed characteristics and other vital signatures such as machine back-EMF/flux and motor current signatures (MCS). The present research study develops and illustrates a method to diagnose physical magnet defects (fault) in PMAC machines by estimating the machine torque/back-EMF constant, Ke. The constant Ke is a measure of magnet strength exhibiting the health of rotor PMs, indicative of faults. Advanced research studies and investigations are carried out to establish motor approximations and signature-based analysis as significant viable tools for diagnosing machine faults even under load conditions.

alternating current↗
NASA NTRS1979

Characteristics of the wake of a lightly loaded compressor or fan rotor

An experimental investigation was carried out to evaluate the properties of the rotor fan or compressor wake in order to understand the structure of the wake. This included a study of profile shape, decay characteristics, effects of rotation, and effects of varying blade loading on the wake. Rotating tri-axial hot-wire probe measurements were reported which represent the first systematic data in the near wake region of the rotor wake using this technique. It is found that the radial, tangential, and axial components of mean velocities and turbulence intensities decay very rapidly near the rotor blade trailing edge, and that increased blade loading reduces the decay rates of axial and tangential mean velocity defects and radial velocities in the wake. In particular, the presence of an almost constant wake width region for increasing axial distance shows the effects of three-dimensionality on the rotor wake flow. Other conclusions are also given.

Reynolds, B. D.↗
NASA NTRS2004

Scatter in Carbon/Silicon Carbide (C/SiC) Composites Quantified

Carbon-fiber-reinforced silicon carbide matrix (C/SiC) composites processed by chemical vapor infiltration are candidate materials for aerospace thermal structures. Carbon fibers can retain properties at very high temperatures, but they are known to have poor oxidation resistance in adverse, high-temperature environments. Nevertheless, the combination of CVI-SiC matrix with higher stiffness and oxidation resistance, the interfacial coating, and additional surface-seal coating provides the necessary protection to the carbon fibers, and makes the material viable for high-temperature space applications operating under harsh environments. Furthermore, C/SiC composites, like other ceramic matrix composites (CMCs), exhibit graceful non-catastrophic failure because of various inherent energy dissipating mechanisms. The material exhibits nonlinearity in deformation even at very low stress levels. This is the result of the severe matrix microcracking present in the as processed composite because of large differences between the coefficients of thermal expansion of the fiber and the matrix. Utilization of these advanced composites in next generation space vehicles will require innovative structural configurations, updated materials, and refined analyses. Structural safety issues for these vehicles are in direct competition with performance and cost. One would have to quantify the uncertainties associated with the design using formal probabilistic methods. Specifically four fundamental aspects on which analyses are based-- (1) loading conditions, (2) material behavior, (3) geometrical configurations, and (4) structural connections between the composite components and baseline structure--are stochastic in nature. A direct way to formally account for uncertainties is to develop probabilistic structural analysis methods where all participating variables are described by appropriate probability density functions. The present work, however, focuses on analyzing the stochastic material behavior of these advanced composites using formal probabilistic analysis methods. Often, some of the desirable property characteristics that allow composites to offer advantages over conventional structural materials (like tailoring of composite properties) and the complexity are in fact responsible for their greater statistical variability and the requirements for more characterization tests. Composite properties are anisotropic as well, having different properties in different directions. This means that characterization of a property such as stiffness--which will vary greatly depending on the orientation of the fiber relative to the direction of the testing--must be repeated for several different directions and loading conditions. The fabrication process for composites also introduces statistical variations in properties and geometry. A composite part is produced in a number of steps, each of which introduces statistical variability. The matrix is usually produced from a combination of raw materials; and the fiber, which has its own set of properties, is often coated or surface treated, introducing yet another source of variability.

Murthy, Pappu L. N.↗
NASA NTRS2007

In-Plane Cracking Behavior and Ultimate Strength for 2D Woven and Braided Melt-Infiltrated SiC/SiC Composites Tensile Loaded in Off-Axis Fiber Directions

The tensile mechanical properties of ceramic matrix composites (CMC) in directions off the primary axes of the reinforcing fibers are important for architectural design of CMC components that are subjected to multi-axial stress states. In this study, 2D-woven melt-infiltrated (MI) SiC/SiC composite panels with balanced fiber content in the 0 degree and 90 degree directions were tensile loaded in-plane in the 0 degree direction and at 45 degree to this direction. In addition, a 2D triaxially-braided MI composite panel with balanced fiber content in the plus or minus 67 degree bias directions and reduced fiber content in the axial direction was tensile loaded perpendicular to the axial direction tows (i.e., 23 degrees from the bias fibers). Stress-strain behavior, acoustic emission, and optical microscopy were used to quantify stress-dependent matrix cracking and ultimate strength in the panels. It was observed that both off-axis loaded panels displayed higher composite onset stresses for through-thickness matrix cracking than the 2D-woven 0/90 panels loaded in the primary 0 degree direction. These improvements for off-axis cracking strength can in part be attributed to higher effective fiber fractions in the loading direction, which in turn reduces internal stresses on critical matrix flaws for a given composite stress. Also for the 0/90 panel loaded in the 45 degree direction, an improved distribution of matrix flaws existed due to the absence of fiber tows perpendicular to the loading direction. In addition, for the +67/0/-67 braided panel, the axial tows perpendicular to the loading direction were not only low in volume fraction, but were also were well separated from one another. Both off-axis oriented panels also showed relatively good ultimate tensile strength when compared to other off-axis oriented composites in the literature, both on an absolute strength basis as well as when normalized by the average fiber strength within the composites. Initial implications are discussed for constituent and architecture design to improve the directional cracking of SiC/SiC CMC components with MI matrices.

Morscher, Gregory N.↗
DOE OSTI2020

Frequency Analysis of Solar PV Power to Enable Optimal Building Load Control

In this paper, we present a flexibility estimation mechanism for buildings’ thermostatically controlled loads (TCLs) to enable the distribution level consumption of the majority of solar photovoltaic (PV) generation by local building TCLs. The local consumption of PV generation provides several advantages to the grid operation as well as the consumers, such as reducing the stress on the distribution network, minimizing voltage fluctuations and two-way power flows in the distribution network, and reducing the required battery storage capacity for PV integration. This would result in increasing the solar PV generation penetration levels. The aims of this study are twofold. First, spectral (frequency) analyses of solar PV power generation together with the power consumption of multiple building TCLs (such as heating, ventilation, and air conditioning (HVAC) systems, water heaters, and refrigerators) are performed. These analyses define the bandwidth over which these TCLs can operate and also describe the PV generation frequency bandwidth. Such spectral analyses, in frequency domain, can help identify the flexible components of PV generation that can be consumed by the various TCLs through optimal building load utilization. Second, a quadratic optimization problem based on model predictive control is formulated to allow consuming most of the low and medium frequency content of the PV power locally by building TCLs, while maintaining occupants’ comfort and TCLs’ physical constraints. The solution to the proposed optimization problem is achieved using optimal control strategies. Numerical results show that most of the low and medium frequency content of the PV generation can be consumed locally by building TCLs. The remaining high-frequency content of the PV generation can then be stored/offset using energy storage systems.

14 SOLAR ENERGY↗
NASA NTRS2007

Reliability and Creep/Fatigue Analysis of a CMC Component

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight and enable higher operating temperatures requiring less cooling; thus leading to increased engine efficiencies. There is a need for convenient design tools that can accommodate various loading conditions and material data with their associated uncertainties to estimate the minimum predicted life as well as the failure probabilities of a structural component. This paper presents a review of the life prediction and probabilistic analyses performed for a CMC turbine stator vane. A computer code, NASALife, is used to predict the life of a 2-D woven silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) turbine stator vane due to a mission cycle which induces low cycle fatigue and creep. The output from this program includes damage from creep loading, damage due to cyclic loading and the combined damage due to the given loading cycle. Results indicate that the trends predicted by NASALife are as expected for the loading conditions used for this study. In addition, a combination of woven composite micromechanics, finite element structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Results indicate that reducing the scatter in proportional limit strength of the vane material has the greatest effect in improving the overall reliability of the CMC vane.

Murthy, Pappu L. N.↗
DOE OSTI2025

Maturing Rational Design Methodologies and Industry Consensus Engineering Standards: Critical Fastened Joints - Solar PV Industry

Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.

14 SOLAR ENERGY↗
DOE OSTI2022

Characterizing Plug Load Energy Use and Savings Potential in Army Buildings

The Assistant Secretary of the Army (Installations, Energy and Environment) tasked the Pacific Northwest National Laboratory to examine plug loads in typical Army buildings. Plug loads (also known as miscellaneous electric loads (MELs)) represent the electricity used by appliances and devices that are plugged in or hardwired and serve functions outside of a building’s core end uses. Common plug loads include computers, printers, copiers, networking devices, refrigerators, and vending machines. They also include personal electronic devices such as televisions, smart phones, tablets, and gaming systems. Examples of hardwired MELs include elevators, air compressors, and fire and security systems. The findings from this study confirm that significant energy is consumed within Army buildings by plug load devices and hardwired MEL equipment. A number of opportunities are identified for reducing unnecessary energy use that could save the Army over $5 million per year when broadly applied. Army regulations clearly spell out expectations for the purchase and operation of information technology equipment (computers, laptops, monitors, printers, and multi-function devices). However, the policies regarding the shutdown or activation of sleep and other lower power modes after 30 minutes of inactivity (15 minutes for monitors) do not appear to be consistently followed. There are many effective approaches and pathways for impacting change as it relates to improving awareness, implementing measures, and adjusting behaviors to identify and reduce plug load energy use. The Army should prioritize and consider deploying all of these to better understand and manage plug load equipment to save energy and enhance resilience across their facilities. Engaging the building occupants who use these devices daily via outreach and education should be a strong component of the strategy. The focus should be on reducing waste without sacrificing productivity or the benefits that many of these devices provide. Continued evaluation of plug loads beyond that performed here is important to gather lessons from additional building and equipment types, and to stay aware of evolving device technology and management options. This will highlight additional needs for policies, best practices, control technologies, and education of personnel to achieve real reductions in energy waste from plug load equipment. It is recommended that this study may serve as the foundation for a broader and sustained focus on plug loads and MELs, towards simultaneously enhancing the productivity, readiness, and resilience of the Army while reducing energy use and demand, and freeing up resources to better support the mission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1985

Vibrations and structureborne noise in space station

Theoretical models were developed capable of predicting structural response and noise transmission to random point mechanical loads. Fiber reinforced composite and aluminum materials were considered. Cylindrical shells and circular plates were taken as typical representatives of structural components for space station habitability modules. Analytical formulations include double wall and single wall constructions. Pressurized and unpressurized models were considered. Parametric studies were conducted to determine the effect on structural response and noise transmission due to fiber orientation, point load location, damping in the core and the main load carrying structure, pressurization, interior acoustic absorption, etc. These analytical models could serve as preliminary tools for assessing noise related problems, for space station applications.

Vaicaitis, R.↗
NASA NTRS2019

Hypervelocity Impact Performance of 3D Printed Aluminum Panels

With the continued development of additive manufacturing methods, control over the shape of ligaments, cell regularity, and macroscopic shape can all be easily tuned. This capability allows for tailoring of component architecture and promotes potential mass savings in a space vehicle structure. Additionally, it allows one the flexibility of combining structural elements such as MMOD protection and vehicle stiffness for launch loads for an overall mass reduction. At NASA JSC this technology is being explored in many different ways with the goal being a multifunctional structural component. For this study, four different types of aluminum panels have been 3D printed for testing, three being of a body centric cubic (BCC) lattice structure core and one being kelvin cell structure core. All samples have a 5.33 cm (0.05”) nominally thick aluminum face sheet printed on the front and back side of each panel, with all core materials having a 5.08 cm (2.0”) nominal thickness (see Table 1 for test sample summary and Figures 1 – 2 for sample illustrations). These tests will evaluate the performance of 3D printed aluminum panels under hypervelocity impact (HVI) conditions. The hypervelocity impact tests are being conducted at the JSC White Sands Test Facility (WSTF) Remote Hypervelocity Test Laboratory (RHTL), located in Las Cruces, New Mexico. All tests will be conducted with a 3.4mm Al 2017-T4 sphere at 6.8 km/s impacting at 0° to surface normal (i.e., impacting with no obliquity). Each sample will be trapped between two metal frames, with gasket material residing between the sample and frame, which will be the shipping and testing configuration for all tests. There will be an Al 2017-T4 witness plate staged 5.08 cm (2.0”) from each sample to capture signature of debris, if the rear face sheet of the sample were to perforate from the HVI test event.

Davis, B. A.↗
NASA NTRS1983

Weight and Balance for the Airmass Incorporated Sunburst Model C Ultralight

The results of the weight and balance determination done for an ultralight aircraft are presented. The weight and balance determination encompassed finding weight and center of gravity of each component, determining the center of gravity of the ultralight in an X, Y, Z reference plane, and calculating the mass moments and products of inertia. The relations were calculated for various pilot weights and fuel loadings. The fuel varied from empty to five gallons (31.05 lbs), and the pilots ranged from 90 to 260 pounds. The weighings of components total 277.48 lbs (no pilot and no fuel).

Source record↗
NASA NTRS2009

Damage Arresting Composites for Shaped Vehicles

This report describes the development of a novel structural solution that addresses the demanding fuselage loading requirements for the Hybrid Wing or Blended Wing Body configurations that are described in NASA NRA subtopic A2A.3, "Materials and Structures for Wing Components and Non-Circular Fuselage." The phase I portion of this task includes a comprehensive finite element model-based structural sizing exercise performed using the BWB airplane configuration to generate internal loads and fuselage panel weights for an advanced Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) structural concept. An accompanying element-level test program is also described which substantiates the analytical results and calculation methods used in the trade study. The phase II plan for the continuation of this research is also included herein.

Velicki, Alex↗
DOE OSTI2022

Numerical analysis of soot emissions from gasoline-ethanol and gasoline-butanol blends under gasoline compression ignition conditions

In the present work, computational fluid dynamics (CFD) simulations of a single-cylinder gasoline compression ignition (GCI) engine were performed to investigate the impact of blending two biofuels, ethanol and n-butanol, with gasoline on the trade-off between combustion phasing and soot emissions under low load conditions. Here, in order to represent market gasoline (RD5-87), a four-component toluene primary reference fuel (TPRF) + ethanol (ETPRF) surrogate (with 20% ethanol by mole; E20) was formulated using a neural network based octane predictor such that the surrogate had the same ethanol content, Research Octane Number (RON) and Octane Sensitivity (S). In addition, a novel skeletal kinetic mechanism for ETPRF and TPRF + n-butanol (BTPRF) blends, incorporating polycyclic aromatic hydrocarbon (PAH) chemistry, was developed. A three-dimensional (3D) engine CFD formulation employing the skeletal mechanism, adaptive mesh refinement (AMR), finite-rate chemistry approach, and hybrid method of moments (HMOM) was adopted to capture the in-cylinder combustion phenomena and soot emissions. The engine CFD model was validated against RD5-87 experimental data for a broad range of start-of-injection (SOI) timings (-21/-27/-36/-45 crank angle degrees (CAD) after top-dead center (aTDC)), with respect to in-cylinder pressure, heat release rate, combustion phasing, and soot emissions. The closed-cycle simulation results were analyzed to elucidate the non-monotonic trend of soot emissions versus SOI timing: SOI-36 > SOI-45 > SOI-21 > SOI-27. Thereafter, the validated CFD model was employed to simulate the combustion of a gasoline-ethanol blend with 45% (by mole) ethanol (E45) and a gasoline-butanol blend with 45% (by mole) n-butanol (B45) under the same operating conditions to study the effects of fuel composition and SOI timing on combustion phasing and soot emissions. The sooting propensity followed the trend: B45 > E20 > E45 at all SOI timings. Overall, it was observed that the autoignition propensity was primarily related to fuel chemistry. On the other hand, sooting propensity showed strong coupling with both fuel chemistry and physical properties, with greater impact of fuel physical properties at advanced SOI timings.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Mitigating humidity interference in chemiresistive hydrogen sensors through hydrophobic surface functionalization

Chemiresistive gas sensors based on semiconductor metal oxides, such as tin dioxide (SnO₂), are indispensable for detecting and monitoring toxic gases and pollutants, making them critical components in industrial and environmental applications. To enhance their performance, the metal oxides are loaded with noble metals such as palladium (Pd). However, ambient humidity poses a significant challenge to their performance. The presence of adsorbed water molecules on the oxide surface can considerably impair sensor sensitivity and overall performance. To address this issue, in this paper, we report on the application of an ultrathin, hydrophobic layer of hexamethyldisilazane to the surface of a Pd/SnO 2 sensor. This study investigates the influence of hydrophobic surface modifications on the metal oxide interface, focusing on their impact on sensor sensitivity and selectivity. The resulting sensor exhibits superior hydrogen sensing capabilities, operating effectively at low temperatures even in high humidity environments. Furthermore, the hydrophobic modification reduces the sensor’s susceptibility to interfering gases, thus enhancing its selectivity. The combined enhancements in moisture resistance and selectivity achieved through HMDS surface modification, along with the superior sensitivity of Pd/SnO₂ sensors, facilitate the development of gas sensors with enhanced humidity tolerance and broader applications.

Chemiresistive gas sensors↗
DOE OSTI2026

A mild calcium carbonate treatment improves moisture resistance and mechanical/interfacial properties of jute and hemp fibers

Natural fibers are attractive, sustainable reinforcements, but often exhibit high moisture uptake and weak bonding with polymer matrices. In this study, jute and hemp were treated by immersion in aqueous calcium carbonate (CaCO3) suspensions (10–40?wt.%, 1.5?h, room temperature) and were characterized by scanning electron microscopy (SEM), X-ray diffraction (XRD), moisture sorption testing, single-fiber tensile testing, and bundle pull-out testing. SEM showed granular CaCO3 deposition on fiber surfaces, with particulates bridging surface voids and microcracks. At 40 wt.% CaCO3, equilibrium moisture uptake decreased to ~5% (hemp) and ~3% (jute), while tensile strength increased to ~904 MPa (hemp) and ~960 MPa (jute). Apparent interfacial shear strength from pull-out testing increased up to ~1.35 MPa (hemp) and ~0.56 MPa (jute). These results indicate that CaCO3 deposition is a mild, scalable surface treatment that improves moisture resistance, fiber tensile strength, and interfacial load transfer relevant to semi-structural composite applications, including interior and secondary automotive components.

Calcium carbonate treatment↗