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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 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

On the Use of Surfactant-Complexed Chitosan for Toughening 3D Printed Polymethacrylate Composites

This work reports a simple approach to prepare toughened 3D-printed polymethacrylate (PMA) composites using surfactant-modified chitosan (SMCS) particles at loadings between 2–10 wt%. Chitosan (CS) is modified with anionic surfactant, sodium dodecyl sulfate, via ionic complexation to facilitate compatibility and dispersion of CS to PMA matrix by non-covalent interactions between the components. The study successfully demonstrates high-accuracy 3D printing of composites with significant improvements in the overall mechanical properties. The composite with the best loading of 8 wt% SMCS shows a tensile modulus of 1.23 ± 0.05 GPa, a tensile strength at 49.8 ± 0.96 MPa, a yield stress at 33.3 ± 1.48 MPa, and a strain-at-ailure 10.3 ± 0.61%, which are 45%, 40%, 32%, and 68% higher than neat PMA, respectively. This provides a significant improvement in toughness at 4.92 ± 0.55 MJ m -3 for the composite, 184% higher than that of neat PMA. The marked increase in toughness is due to enhanced filler-matrix interactions which improve the ability of the 3D printed composite to absorb energy under tensile load. The results from this work provide new understandings into the strategies for design and preparation of stereolithography 3D printed materials reinforced with toughening fillers from renewable resources.

36 MATERIALS SCIENCE↗
NASA NTRS1998

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA Langley Research Center for investigating integrated cryogenic propellant tank systems for a Reusable Launch Vehicle are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, Thermal Protection System (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗
NASA NTRS2005

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA, Langley Research Center (LaRC) for investigating integrated cryogenic propellant tank systems for a reusable launch vehicle (RLV) are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, thermal protection system (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗
NASA NTRS2004

Effect of Surface Impulsive Thermal Loads on Fatigue Behavior of Constant Volume Propulsion Engine Combustor Materials

The development of advanced high performance constant-volume-combustion-cycle engines (CVCCE) requires robust design of the engine components that are capable of enduring harsh combustion environments under high frequency thermal and mechanical fatigue conditions. In this study, a simulated engine test rig has been established to evaluate thermal fatigue behavior of a candidate engine combustor material, Haynes 188, under superimposed CO2 laser surface impulsive thermal loads (30 to 100 Hz) in conjunction with the mechanical fatigue loads (10 Hz). The mechanical high cycle fatigue (HCF) testing of some laser pre-exposed specimens has also been conducted under a frequency of 100 Hz to determine the laser surface damage effect. The test results have indicated that material surface oxidation and creep-enhanced fatigue is an important mechanism for the surface crack initiation and propagation under the simulated CVCCE engine conditions.

Zhu, Dongming↗
NASA NTRS1989

The mixed-mode bending method for delamination testing

A mixed-mode bending (MMB) test procedure is presented which combines double cantilever beam mode-I loading and end-notch flexure mode II loading on a split, unidirectional laminate. The MMB test has been analyzed by FEM and by beam theory in order to ascertain the mode I and mode II components' respective strain energy release rates, G(I) and G(II); these analyses indicate that a wide range of G(I)/G(II) ratios can be generated by varying the applied load's position on the loading lever. The MMB specimen analysis and test procedures are demonstrated for the case of AS4/PEEK unidirectional laminates.

Reeder, James R.↗
NASA NTRS1993

Temporal and spatial mapping of surface albedo and atmospheric dust opacity on Mars

The Mariner 9 and Viking provided abundant evidence that eolian processes are active over much of the surface of Mars. Past studies have demonstrated that variations in regional albedo and wind-streak patterns are indicative of sediment transport through a region, while thermal inertia data (derived from the Viking Infrared Thermal Mapper (IRTM) dataset) are indicative of the degree of surface mantling by dust deposits. The visual and thermal data are therefore diagnostic of whether net erosion or deposition of dust-storm fallout is taking place currently and whether such processes have been active in a region over the long term. These previous investigations, however, have not attempted to correct for the effects of atmospheric dust loading on observations of the martian surface, so quantitative studies of current sediment transport rates have included large errors due to uncertainty in the magnitude of this 'atmospheric component' of the observations. We have developed a radiative transfer model that allows the atmospheric dust opacity to be determined from IRTM thermal observations. Corrections for the effects of atmospheric dust loading on observations of surface albedo can also be modeled. This approach to determining 'dust-corrected surface albedo' incorporates the atmospheric dust opacity, the single-scattering albedo and particle phase function of atmospheric dust, and the bidirectional reflectance of the surface, and it accounts for variable lighting and viewing geometry.

Lee, S. W.↗
DOE OSTI2020

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Efficient use of bit planes in the generation of motion stimuli

The production of animated motion sequences on computer-controlled display systems presents a technical problem because large images cannot be transferred from disk storage to image memory at conventional frame rates. A technique is described in which a single base image can be used to generate a broad class of motion stimuli without the need for such memory transfers. This technique was applied to the generation of drifting sine-wave gratings (and by extension, sine wave plaids). For each drifting grating, sine and cosine spatial phase components are first reduced to 1 bit/pixel using a digital halftoning technique. The resulting pairs of 1-bit images are then loaded into pairs of bit planes of the display memory. To animate the patterns, the display hardware's color lookup table is modified on a frame-by-frame basis; for each frame the lookup table is set to display a weighted sum of the spatial sine and cosine phase components. Because the contrasts and temporal frequencies of the various components are mutually independent in each frame, the sine and cosine components can be counterphase modulated in temporal quadrature, yielding a single drifting grating. Using additional bit planes, multiple drifting gratings can be combined to form sine-wave plaid patterns. A large number of resultant plaid motions can be produced from a single image file because the temporal frequencies of all the components can be varied independently. For a graphics device having 8 bits/pixel, up to four drifting gratings may be combined, each having independently variable contrast and speed.

Mulligan, Jeffrey B.↗
NASA NTRSDate not supplied

Delamination Depth Imaging for Quasi-Static and Fatigue Load Testing Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in composite hat-stiffened panels during both quasi-static and fatigue loading. It has been observed that rapid damage formation produces heating. This is composed of two heat generation components. The first component is an instantaneous response due to an irreversible thermoelastic strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This produces a transient rise in temperature as the heat diffuses to the surface. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is fitted to the data pixel by pixel, to produce imagery of the damage depth. The results are compared to ultrasonic and X-ray CT data.

Passive thermography↗
NASA NTRS1982

Effects of blade loading and rotation on compressor rotor wake in end wall regions

This study was carried out to understand the effects of blade loading and rotation on the rotor end wall flow structure, including the wake. The measurements were taken with a stationary three sensor hot wire located at the exit of a compressor rotor. The signal was ensemble averaged to derive all the three components of velocity and six components of stresses at the exit. Measurements were made at two different rotational speeds (1753 and 1010 rpm) and at two differing blade loadings at several radii near the hub and the annulus wall. The wake decay in the annulus wall region is found to be much more rapid than the mid span regions. Furthermore, both the loading and rotation of the blade have appreciable influence on the end wall flow and wake structure. Interaction of the annulus and hub wall boundary layers (and secondary flow resulting from these) have appreciable influence on the wake structure in the endwall regions.

Lakshminarayana, B.↗
NASA NTRS1993

Analysis of delamination in cross-ply laminates initiating from impact induced matrix cracking

Two-dimensional finite element analyses of (02/90(8)/02) glass/epoxy and graphite/epoxy composite laminates were performed to investigate some of the characteristics of damage development due to an impact load. A cross section through the thickness of the laminate with fixed ends, and carrying a transverse load in the center, was analyzed. Inclined matrix cracks, such as those produced by a low-velocity impact, were modeled in the 90 deg ply group. The introduction of the matrix cracks caused large interlaminar tensile and shear stresses in the vicinity of both crack tips in the 0/90 and 90/0 interfaces, indicating that matrix cracking may give rise to delamination. The ratio of Mode I to total strain energy release rate, G(I)/G(total), at the beginning of delamination, calculated at the two (top and bottom) matrix crack tips was 60 and 28 percent, respectively, in the glass/epoxy laminate. The corresponding ratio was 97 and 77 percent in the graphite/epoxy laminate. Thus, a significant Mode I component of strain energy release rate may be present at the delamination initiation due to an impact load. The value of strain energy release rate at either crack tip increased due to an increase in the delamination length at the other crack tip and may give rise to an unstable delamination growth under constant load.

Salpekar, S. A.↗
NASA NTRS1991

Analysis of delamination in cross ply laminates initiating from impact induced matrix cracking

Several two dimensional finite element analyses of (0 sub 2/90 sub 8/0 sub 2) glass/epoxy and graphite-epoxy composite laminates were performed to study some of the characteristics of damage development due to an impact load. A cross section through the thickness of the laminate with fixed ends, and carrying a transverse load in the center was analyzed. Inclined matrix cracks such as those produced by low velocity impact were modeled in the 90 deg ply group. The introduction of the matrix cracks caused large interlaminar tension and shear stresses in the vicinity of both crack tips in the 0/90 and 90/0 interfaces. The large interlaminar stresses at the ends of the matrix cracks indicate that matrix cracking may give rise to delamination. The ratio of mode I to total strain energy release rate at the beginning of delamination calculated at the two matrix crack tips was 60 and 28 pct., respectively, in the glass/epoxy laminate. The corresponding ratio was 97 and 77 pct. in the graphite-epoxy laminate. Thus, a significant mode I component of strain energy release rate may be present at the delamination initiation due to an impact load.

Salpekar, S. A.↗
DOE OSTI2025

Active Divertor Heat Flux Control using Impurity Powder Dropper

Divertor plasma-facing components (PFCs) in a tokamak are typically designed to withstand average steady-state heat loads of about 5–10 MW/m 2 , a limit that applies to both solid and liquid lithium (LL) PFCs. Exceeding these design values can result in surface damage to tungsten PFCs or excessive lithium (Li) evaporation in liquid lithium divertor (LLD) PFCs. Since exceeding the divertor heat load limits has serious consequences, it is therefore prudent to develop a tool to reduce the divertor heat load and bring the heat load to within the design limit without affecting the plasma performance. Active low Z impurity injection such as Li has been suggested as a potential solution to mitigate excess heat flux as suggested previously, given that non-coronal radiation can be quite large ~ 20–30 MJ per mole of injected Li. Li is considered desirable for reducing the edge neutral recycling helping to improve plasma energy confinement. In this paper, we model the Impurity Power Dropper (IPD) to investigate its potential of divertor heat flux control. The IPD is typically located at the top of the tokamak device and uses a vertical drift tube of a few meters. In the 2 m drift tube case, the IPD powder is accelerated to ~ 6 m/sec before reaching the plasma with the upper divertor configuration, matching the condition for the in-board side pellet injection case. By modeling the IPD geometry we determined the IPD powder deposition profile, and thus the non-coronal radiation and ionization profiles in time as well. From the enhanced radiation power loss, it is therefore possible to reduce the divertor heat load using the divertor simulation code. In conclusion, the IPD divertor heat flux control can be tested in the facilities with IPD including ST-40, DIII-D, EAST, WEST and NSTX-U.

Active lithium injection↗
DOE OSTI2022

Control of High-Temperature Static and Transient Thermomechanical Behavior of SiMo Ductile Iron by Al Alloying

Abstract Silicon and molybdenum ( SiMo ) ductile iron is commonly used for exhaust manifolds because these components experience thermal cycling in oxidizing environment, which requires resistance to fatigue during transient thermomechanical loads. Previous studies have demonstrated that alloying elements, such as Al , to SiMo ductile iron reduces the amount of surface degradation during static high-temperature exposure. However, deterioration of sphericity of the graphite nodules and a decrease in ductility could affect the tendency of cracking during thermal cycling. In this article, the effect of Al alloying on static and transient thermomechanical behavior of SiMo ductile iron was investigated to optimize the amount of Al alloying. A thermodynamic approach was used to confirm the effect of the Al alloying on the phase transformations in two SiMo cast irons, alloyed by 1.8% Al and 3% Al . These two alloys were cast in a laboratory along with the baseline SiMo ductile iron. Several experimental methods were used to evaluate the dimensional stability, physical properties, static oxidation, and failure resistance during constrained thermal cycling testing to compare their high-temperature capability. Experimental results verified that Al alloying increases the temperature range and decreases volume change during eutectoid transformation, which together with enhancement of oxidation protection improved the dimensional stability. Thermocycling tests showed that the number of cycles to failure depends on the amount of Al alloying and the applied high-temperature exposure during each cycle. SEM/EDX, high-resolution TEM and µCT analysis were used to verify the mechanism resulting from the Al alloying protection. It was shown that an optimal level of Al alloying for balancing oxidation and thermal cracking resistance depends on thermomechanical conditions of application.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Holistic energy analysis method for thermal management architectures of data centers

Modern high-performance computing (HPC) data centers (DCs), particularly those supporting energy-intensive artificial intelligence (AI) workloads, face escalating thermal management challenges that degrade performance through thermal throttling and drive up cooling power consumption and operational costs. To address this challenge, many have developed a wide variety of thermal management solutions (single-phase, two-phase, direct, indirect, hybrid, and more) which attempt to cool HPC DCs effectively while attempting to minimize overall system power consumption. However, the analysis of these solutions and methods to effectively compare one with another is lacking. Overall power usage effectiveness (PUE) and total-power usage effectiveness (TUE) provide a metric to quantify power consumption but fail to identify components in the system which require further optimization. To address this, we propose a holistic analytical framework – the waterfall diagram (WFD) – which leverages a waterfall chart methodology, offering a comprehensive visualization of both the thermal management system loop and heat flow pathways from individual server components to the outdoor ambient. Use of the WFD enables graphical estimations of power efficiency and cooling performance across each component of a DC cooling system and complements Sankey-style energy flow visualizations by additionally resolving stage-wise temperature changes and incremental TUE contributions. The framework is used in conjunction with simulation-based approaches, to conduct a detailed pressure drop and flow distribution analysis aimed at identifying the optimal coolant distribution architecture for a single-phase direct-to-chip water-cooled DC, which serves as the baseline for subsequent WFD analysis. Among the evaluated architectures, the 3 U modular coolant distribution architecture is found to demonstrate the best performance, considering minimal pressure drop and uniform flow distribution. In addition, TUE is calculated for each cooling loop component based on its associated pressure drop and corresponding pumping power, which are integrated into the WFD. This correlation between TUE and local temperature offers immediate insight into the power efficiency and thermal performance contributions of individual components, facilitating further development and optimization. Examples of WFD applications are presented under varying thermal loads and ambient conditions, demonstrating reasonable cooling strategies. Notably, the 3 U modular architecture maintains a consistent chip case temperature of 85°C, achieving a TUE of 1.016 at ambient temperature of 47°C, and a TUE of 1.026 at ambient temperature of 52°C. The WFD methodology provides an efficient, holistic, and streamlined framework for DC thermal management architecture assessment and enables design optimization which is important for addressing the thermal-fluidic energy challenges of current and next-generation DCs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Seasonal Reconfiguration of Electrical Distribution Systems to Mitigate the Impact of Electric Vehicle Charging

Power grids face challenges in their infrastructure related to the integration of electric vehicles (EV). In particular, EV charging stations may induce instability in key system parameters such as substantial voltage drops, active power losses, and transformer overload due to high demand during charging periods. This article presents a seasonal reconfiguration strategy based on the differential evolution (DE) algorithm, aimed at enhancing system performance under highly variable and stochastic load profiles, particularly those driven by EV charging. The DEA algorithm is hybridized with the find-union (FU) algorithm to efficiently ensure network radiality throughout the optimization process. The proposed methodology is validated on a hybrid distribution system composed of the IEEE 33-bus network, a modified IEEE 13-bus system, and a specific 13-bus microgrid. Results have demonstrated that seasonal reconfiguration significantly reduces active power losses and mitigates transformer loading during critical demand hours, thereby quantifiably increasing the system’s performance. As an integral component of the proposed approach, an analysis of CO2 emissions associated with energy losses is included, allowing a contextualized assessment of the environmental benefits of seasonal reconfiguration in various geographical areas.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Pressure Spike in The LBNF Absorber Core s Gun Drilled Cooling Channel from an Accident Beam Pulse

The LBNF Absorber consists of thirteen 6061-T6 aluminum core blocks. The core blocks are water cooled with de-ionized (DI) water which becomes radioactive during beam operations. The cooling water flows through gun-drilled channels in the core blocks. The cooling water is supplied by the LBNF Absorber Radioactive Water (RAW) cooling system which is designed as per ASME B31.3 Normal Fluid Service [1]. An uninhibited beam accident pulse striking the water channels was identified as a credible accident scenario. In this study, it is assumed that the beam pulse hits the Absorber directly without interacting with any of the other upstream beamline components. The beam parameters used for the LBNF beam are 120 GeV, 2.4 MW with a 1.2 s cycle time. The accident pulse lasts for 10 μs. The maximum energy is deposited in the 3rd aluminum core block. For the sake of simplicity, it is assumed that the accident pulse strikes the 1 in. ID water channel directly. The analysis here simulates the pressure rise in the water during and after the beam pulse and its effects on the aluminum piping components that deliver water to the core blocks. The weld strengths as determined by the Load and Resistance Factor Design (LRDF) and the Allowable Strength Design (ASD) are compared to the forces generated in the weld owing to the pressure spike. A transient structural analysis was used to determine the equivalent membrane, peak, and bending stresses and they were com-pared to allowable limits.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Reversible Fuel Cell Stacks with Integrated Water Management

Regenerative fuel cell/electrolyzers have long held promise as energy storage devices. Due to their small footprint and their ability to separately size the power and storage functions, they have many advantages over batteries, particularly for remote or deployable systems. A unitized regenerative fuel cell is proposed that takes advantage of three new technologies. The first is a H 2 /O 2 unitized regenerative stack that Giner, Inc. (Giner) has developed that combines a fuel cell and electrolyzer stack, eliminating one of the electrochemical stacks, the most expensive component in regenerative fuel cell systems. The second is an oxygen catalyst with low PGM loadings generated through Reactive Spray Deposition Technology (RSDT). The third is an amphiphilic microporous layer (AMPL) structure to greatly aid water management in both operational modes.

08 HYDROGEN↗