Results for “stacking engineering” — Page 8

NASA NTRS1982

Cell module and fuel conditioner development

The efforts performed to develop a phosphoric acid fuel cell (PAFC) stack design having a 10 kW power rating for operation at higher than atmospheric pressure based on the existing Mark II design configuration are described. The work involves: (1) Performance of pertinent functional analysis, trade studies and thermodynamic cycle analysis for requirements definition and system operating parameter selection purposes, (2) characterization of fuel cell materials and components, and performance testing and evaluation of the repeating electrode components, (3) establishment of the state-of-the-art manufacturing technology for all fuel cell components at Westinghouse and the fabrication of short stacks of various sites, and (4) development of a 10 kW PAFC stack design for higher pressure operation utilizing the top down systems engineering approach.

Feret, J. M.↗

NASA NTRS1981

Cell module and fuel conditioner development

A phosphoric acid fuel cell (PAFC) stack design having a 10 kW power rating for operation at higher than atmospheric pressure based on the existing Mark II design configuration is described. Functional analysis, trade studies and thermodynamic cycle analysis for requirements definition and system operating parameter selection purposes were performed. Fuel cell materials and components, and performance testing and evaluation of the repeating electrode components were characterized. The state of the art manufacturing technology for all fuel cell components and the fabrication of short stacks of various sites were established. A 10 kW PAFC stack design for higher pressure operation utilizing the top down systems engineering aproach was developed.

Feret, J. M.↗

NASA NTRS2000

A Comparison of Quasi-Static Indentation and Drop-Weight Impact Testing on Carbon/Epoxy Laminates

This project was initiated to investigate the damage tolerance of polymer matrix composites (PMC). After a low velocity impact-such as the ones that can occur during manufacturing or service there is usually very little visual damage. There are two possible methods to simulate foreign object impact on PMC: static indentation and drop weight impact. A static method for modeling low velocity foreign object impact events for composites can prove to be very beneficial to researchers since much more data can be obtained from a static test than from an impact test. In order to examine if this is feasible, a series of static indentation and low velocity impact tests were performed and compared. Square specimens of different sizes and thicknesses were tested to cover a wide array of low velocity impact events. Laminates with a 45 degree stacking sequence were used since this is a common type of engineering laminate. Three distinct flexural rigidities under two different boundary conditions were tested in order to obtain damage due to large deflections. Comparisons between static indentation and low velocity impact tests were based on the maximum applied transverse load. The dependent parameters examined were dent depth, back surface crack length, delamination area, and load-deflection behavior. Results showed that no distinct differences could be seen between the static indentation tests and the low velocity impact tests, indicating that static indentation tests can be used to simulate low velocity impact events.

Prabhakaran, R.↗

NASA NTRS2011

Estimating Mass of Inflatable Aerodynamic Decelerators Using Dimensionless Parameters

This paper describes a technique for estimating mass for inflatable aerodynamic decelerators. The technique uses dimensional analysis to identify a set of dimensionless parameters for inflation pressure, mass of inflation gas, and mass of flexible material. The dimensionless parameters enable scaling of an inflatable concept with geometry parameters (e.g., diameter), environmental conditions (e.g., dynamic pressure), inflation gas properties (e.g., molecular mass), and mass growth allowance. This technique is applicable for attached (e.g., tension cone, hypercone, and stacked toroid) and trailing inflatable aerodynamic decelerators. The technique uses simple engineering approximations that were developed by NASA in the 1960s and 1970s, as well as some recent important developments. The NASA Mars Entry and Descent Landing System Analysis (EDL-SA) project used this technique to estimate the masses of the inflatable concepts that were used in the analysis. The EDL-SA results compared well with two independent sets of high-fidelity finite element analyses.

Samareh, Jamshid A.↗

NASA NTRS1990

Oscillating flow loss test results in Stirling engine heat exchangers

The results are presented for a test program designed to generate a database of oscillating flow loss information that is applicable to Stirling engine heat exchangers. The tests were performed on heater/cooler tubes of various lengths and entrance/exit configurations, on stacked and sintered screen regenerators of various wire diameters and on Brunswick and Metex random fiber regenerators. The test results were performed over a range of oscillating flow parameters consistent with Stirling engine heat exchanger experience. The tests were performed on the Sunpower oscillating flow loss rig which is based on a variable stroke and variable frequency linear drive motor. In general, the results are presented by comparing the measured oscillating flow losses to the calculated flow losses. The calculated losses are based on the cycle integration of steady flow friction factors and entrance/exit loss coefficients.

Koester, G.↗

DOE OSTI2024

MW-Class SOFC Pilot System Development

The overall objective of this project is to develop a low-cost, efficient, and reliable MWe-class Solid Oxide Fuel Cell (SOFC) power system towards commercial deployment in natural-gas fueled distributed generation applications. This report details the successful completion of all project objectives. The main goals of the project were to develop the conceptual design of a MWe-class SOFC power system, and to complete a techno-economic analysis (TEA) to determine system costs at low-volume production levels of >100MW per year. The combination of the BoP equipment cost and SOFC stack module factory cost provided the net fabrication cost of the selected 1MW SOFC system configuration. The results of the study showed that the cost target of less than $6000/kW is achievable for a FOAK 1MW SOFC system, exclusive of the first-time engineering cost. Also, the project included an exploratory analysis of the factory cost of next generation stack technology based on the Compact Solid-oxide Architecture (CSA) design at a high annual manufacturing rate of one-GW produced in a giga-factory. The BoP capital cost for one giga-watt power production was estimated using learning-curve analysis based on the historical manufacturing cost data related to similar high temperature Molten Carbonate fuel cell systems built by FuelCell Energy (FCE). The giga-factory manufactured SOFC cost estimate combined with the BoP cost at high production rates led to the estimation of entire system capital cost. Ultimately, a Cost of Electricity (COE) analysis was performed including natural gas fuel prices, installation and O&M costs, and stack replacement cost. The results of the techno-economic analysis were summarized by parametric estimation of COE for 1MW SOFC NOAK (Nth-of-a-Kind) system with natural gas prices as a variable parameter.

08 HYDROGEN↗

DOE OSTI2020

Unraveling the influence of non-fullerene acceptor molecular packing on photovoltaic performance of organic solar cells

In non-fullerene organic solar cells, the long-range structure ordering induced by end-group π–π stacking of fused-ring non-fullerene acceptors is considered as the critical factor in realizing efficient charge transport and high power conversion efficiency. Here, we demonstrate that side-chain engineering of non-fullerene acceptors could drive the fused-ring backbone assembly from a π–π stacking mode to an intermixed packing mode, and to a non-stacking mode to refine its solid-state properties. Different from the above-mentioned understanding, we find that close atom contacts in a non-stacking mode can form efficient charge transport pathway through close side atom interactions. The intermixed solid-state packing motif in active layers could enable organic solar cells with superior efficiency and reduced non-radiative recombination loss compared with devices based on molecules with the classic end-group π–π stacking mode. Our observations open a new avenue in material design that endows better photovoltaic performance.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

19.32% Efficiency Polymer Solar Cells Enabled by Fine-Tuning Stacking Modes of Y-Type Molecule Acceptors: Synergistic Bromine and Fluorine Substitution of the End Groups

Here, the success of Y6-type nonfullerene small molecule acceptors (NF-SMAs) in polymer solar cells (PSCs) can be attributed to their unique honeycomb stacking style, which leads to favorable thin-film morphologies. The intermolecular interactions related to the crystallization tendency of these NF-SMAs is closely governed by their electron accepting end groups. For example, the high performance Y6 derivative L8-BO (BTP-4F) presents three types of stacking modes in contrast to two stacking modes of Y6. Hence, it is ultimately interesting to obtain more insight on the packing properties and the preferences influenced by chemical modifications such as end group engineering. This work designs and synthesizes asymmetric and symmetric L8-BO derivatives with brominated end groups and explores the stacking preferences in various modes. The asymmetric BTP-3FBr displays an optimized crystallization tendency and thin film morphology, leading to a decent power conversion efficiency (PCE) of 18.34% in binary devices and a top PCE of 19.32% in ternary devices containing 15 wt% IDIC as the second acceptor.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Extended defects in GaAs/GaAs 1-x Sb x /GaAs (001) heterostructures

The atomic-scale structure of extended defects in GaAs/GaAs 1-x Sb x /GaAs (001) heterostructures has been characterized using aberration-corrected scanning transmission electron microscopy. The defect located at the tensile-strained GaAs(cap)/GaAs 0.34 Sb 0.66 interface had no edge component in the projection plane and is identified as either a dissociated screw dislocation or a partial dislocation dipole. The associated intrinsic stacking fault is bounded by two 30° Shockley partial dislocations of opposite sign. Another defect, located at the compressively-strained GaAs 0.91 Sb 0.09 /GaAs(substrate) interface, is identified as a dissociated 90° dislocation. The associated intrinsic stacking fault is bounded by a 30° Shockley partial dislocation and a partial dislocation with a Burgers vector of either or , where a is the lattice constant. Unpaired atomic columns observed at the cores of the 30° Shockley partial dislocations indicate that both defects belong primarily to the glide set.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Tunable Electronic Energy Level Alignment and Exciton Diversity in Organic–Inorganic van der Waals Heterostructures

van der Waals stacking of two-dimensional (2D) materials offers a powerful platform for engineering material interfaces with tailored electronic and optical properties. While most van der Waals multilayers have featured inorganic monolayers, incorporating molecular monolayers introduces additional degrees of tunability and functionality. Here, in this study, we investigate hybrid bilayers composed of atomically thin perylene-based molecular crystals interfaced with monolayer transition metal dichalcogenides (TMDs), specifically MoS 2 and WS 2 . Using the ab initio many-body perturbation theory within the GW approximation and the Bethe-Salpeter equation approach, we predict emergent properties beyond those of the isolated constituent systems. Notably, we find substantial renormalization of monolayer molecular crystal band gap due to TMD-induced polarization. Furthermore, by varying the TMD monolayer, we demonstrate tuning of the energy level alignment of the bilayer and subsequent control over a diversity of lowest-energy excitons, which include strongly bound hybrid excitons and long-lived charge-transfer excitons. These findings establish organic-inorganic van der Waals heterostructures as a promising class of materials for tunable optoelectronic devices and quantum excitonic phenomena, expanding the design space for low-dimensional systems.

GW-BSE calculations↗

DOE OSTI2026

An end-to-end workflow for executing a classically bootstrapped variational quantum algorithm on an academic quantum computer

Academic quantum computing platforms often face unique challenges in executing quantum workloads due to fragmented software environments and limited engineering support. Unlike commercial ecosystems, academic devices typically evolve without full-stack integration in mind, making it difficult to run complex applications—such as variational quantum algorithms (VQA)—reliably and efficiently. Issues such as incompatible software layers and lack of automated job management significantly increase the overhead of theory-experiment collaboration. To address these challenges, we develop a modular, end-to-end workflow that decouples application-layer code from low-level hardware control, automates circuit submission and result collection, and supports fine-grained circuit-level job scheduling and recovery. The architecture employs a dual-end application programming interface (API) design, enabling robust operation across unstable or resource-constrained hardware backends. For practical use, the framework is lightweight and user-friendly, allowing rapid prototyping of full-stack workflows using basic Python tools. We validate this workflow on a high-fidelity trapped-ion quantum computer by demonstrating a variational quantum eigensolver (VQE) experiment with a classically bootstrapped ansatz initialization technique. The system successfully executed over 60,000 circuits across multiple molecular test cases with minimal human intervention, highlighting the framework’s effectiveness in enabling reproducible, resilient quantum experimentation in academic settings.

Clifford↗

DOE OSTI2024

Evaluation of Naturally Occurring Be-7 Activity on LANL Stack Filter Clumps

Los Alamos National Laboratory (LANL) is responsible for providing solutions to challenging issues through multidisciplinary science, engineering, and technology that impact national security. As part of the Radioactive Air Emissions Management (RAEM) Team, it is our responsibility to ensure LANL operates within the requirements of the Code of Federal Regulations 40 CFR 61, Subpart H, National Emission Standards for Emissions of Radionuclides Other Than Radon From Department of Energy Facilities (Rad-NESHAP). The standard states, “Emissions of radionuclides to the ambient air from Department of Energy facilities shall not exceed those amounts that would cause any member of the public to receive in any year an effective dose equivalent of 10 mrem/yr” (EPA, 2002) During a routine assessment of LANL’s Rad-NESHAP compliance program, an opportunity for improvement was identified that addresses the evaluation of routine stack samples which potentially have naturally occurring radioactive materials (NORM) on the filter media. In the past and based on professional judgment, detections of NORM such as K-40 and Be-7 typically were rejected from the analytical results. The assessment finding suggested developing a technical criterion to ensure that such rejections were justified, comparing actual measured values with anticipated NORM concentrations for various stacks located at LANL. The significance of accepting or rejecting samples as “true” or “NORM” and its impact on the RAEM’s mission and compliance to the regulations is explained later in the document. Additionally, this document will describe the process and calculations for how such results are to be accepted as actual samples “true positive” or rejected as NORM.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

NASA NTRS1984

The Base Engine for Solar Stirling Power

A new concept in Stirling engine technology is embodied in the base engine now being developed at Stirling Thermal Motors, Inc. This is a versatile energy conversion unit suitable for many different applications and heat sources. The base engine, rated 40 kW at 2800 RPM, is a four-cylinder, double-acting variable displacement Stirling engine with pressurized crankcase and rotating shaft seal. Remote-heating technology is incorporated with a stacked-heat-exchanger configuration and a liquid metal heat pipe connected to a distinctly separate combustor or other heat source. High efficiency over a wide range of operating conditions, long life, low manufacturing cost and low material cost are specifically emphasized. The base engine, its design philosophy and approach, its projected performance, and some of its more attractive applications are described.

Meijer, R. J.↗

NASA NTRSDate not supplied

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

NASA NTRSDate not supplied

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

NASA NTRSDate not supplied

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

DOE OSTI2021

High performance protonic ceramic fuel cell systems for distributed power generation

The technology landscape around distributed generation continues to evolve in response to increasing demand for high-efficiency, low-emission, low-cost power generation. While emerging distributed power technologies, such as solid oxide fuel cells (SOFCs), continue to advance, they still face challenges due to their high capital costs, and shorter lifetimes that typically arise from electrochemical stack performance degradation at high operating temperatures (>750 °C). Recent advancements in protonic ceramic fuel cells (PCFCs) offer the potential to mitigate drawbacks of their higher temperature SOFC counterparts by enabling lower operating temperatures (550 °C–600 °C) with acceptable power densities. Here the present work leverages the recent progress in protonic ceramic cell and stack technology development to generate viable system configurations and evaluate the energetic performance potential of PCFC-based systems for stationary power generation. Process system engineering of two water-neutral system concepts, which provide 25 kW of electric power and process hot water, are presented and evaluated through sensitivity studies. Stack design parameters are altered and used to gauge the effect on system performance characteristics, including fuel cell stack and balance-of-plant sizing requirements, and electric and cogeneration efficiencies. The study finds that the potentially high per-pass fuel utilization capability of PCFC stacks could enable unprecedented electric efficiencies approaching 70% without hybridization with other prime movers.

25 ENERGY STORAGE↗

NASA NTRS2018

Turbine Electrified Energy Management (TEEM) For Enabling More Efficient Engine Designs

NASA is investing in Electrified Aircraft Propulsion (EAP) research as part of an effort to assist industry in meeting the future needs of a global aviation market. The integration of electric machines into traditional turbine-based propulsion provides opportunities to change system architectures effecting radical improvements in propulsive efficiency. However, less consideration has been afforded to the utilization of these electrical machines to improve the thermal efficiency and performance of the gas turbine engine. Noting this deficit, a novel operability concept is proposed and is referred to as Turbine Electrified Energy Management (TEEM). The concept is a transient control technology that supplements the main fuel control for the suppression of the natural off-design dynamics associated with changes in engine operating state. Here the electric machines, used as engine actuators during the transient, add or extract torque from the engine shafts to maintain the speed-flow characteristics of steady-state design operation. This greatly reduces the need to maintain transient stall margin stack in the compressors, among other potential benefits. This paper demonstrates the feasibility of the concept in dynamic simulation using a Numerical Propulsion System Simulation (NPSS) engine model of a NASA hybrid electric propulsion concept known as the Parallel Hybrid Electric Turbofan (hFan).

Culley, Dennis E.↗