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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 1,513 records · Page 84
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Using Plate Finite Elements for Modeling Fillets in Design, Optimization, and Dynamic Analysis

A methodology has been developed that allows the use of plate elements instead of numerically inefficient solid elements for modeling structures with 90 degree fillets. The technique uses plate bridges with pseudo Young's modulus (Eb) and thickness (tb) values placed between the tangent points of the fillets. These parameters are obtained by solving two nonlinear simultaneous equations in terms of the independent variables rlt and twallt. These equations are generated by equating the rotation at the tangent point of a bridge system with that of a fillet, where both rotations are derived using beam theory. Accurate surface fits of the solutions are also presented to provide the user with closed-form equations for the parameters. The methodology was verified on the subcomponent level and with a representative filleted structure, where the technique yielded a plate model exhibiting a level of accuracy better than or equal to a high-fidelity solid model and with a 90-percent reduction in the number of DOFs. The application of this method for parametric design studies, optimization, and dynamic analysis should prove extremely beneficial for the finite element practitioner. Although the method does not attempt to produce accurate stresses in the filleted region, it can also be used to obtain stresses elsewhere in the structure for preliminary analysis. A future avenue of study is to extend the theory developed here to other fillet geometries, including fillet angles other than 90 and multifaceted intersections.

Brown, A. M.↗
DOE OSTI2025

CALPHAD-based ICME design of single-step aging to enhance mechanical strength of WAAM Haynes 282

To match the strength of wire-arc additive manufactured Haynes 282 to its wrought counterpart via a single-step aging heat treatment, the CALPHAD (Calculation of Phase Diagrams) method is integrated with physics-based process-structure-property models and experimental validation. The integrated computational materials engineering (ICME) framework simulates the effects of aging on γ′ and M 23 C 6 precipitation and the resulting yield strength. To improve simulation reliability, the interfacial energies between γ/γ′ and γ/M 23 C 6 carbides were estimated by comparison with precipitation kinetic modeling and measured precipitate sizes. γ′ and M23C6 were found to precipitate simultaneously between 640 and 860 °C, producing microstructures similar to those produced by two-step aging. The optimal γ′ size for peak yield stress was calculated to be 20–23 nm. WAAM Haynes 282 aged at 780 °C for 50 h exceeded the mechanical performance of its wrought counterpart subjected to two-step aging, though desired properties can also be achieved at 800 °C for 16 h or less. The error in yield strength is less than 20 MPa, demonstrating good agreement between the modeling framework and experiments. Creep studies showed that WAAM Haynes 282 exceeded the calculated rupture time, reaching 481 h. This proposed methodology can accelerate the design of aging heat treatments for any γ′-strengthened nickel-base alloy, minimizing the resources required for trial-and-error experiments.

CALPHAD↗
DOE OSTI2023

Coupling multi-fidelity xRAGE with machine learning for graded inner shell design optimization in double shell capsules

Bayesian optimization has shown promise for the design optimization of inertial confinement fusion targets. Specifically, in Vazirani et al. [Phys. Plasmas 28 , 122709 (2021)], optimal designs for double shell capsules with graded inner shells were identified using one-dimensional xRAGE simulation yield calculations. While the machine learning models were able to accurately learn and predict one-dimensional simulation target performance, using simulations with higher fidelity would improve design optimization and better match with the expected experimental performance. However, higher fidelity physics modeling, i.e., two-dimensional xRAGE simulations, requires significantly larger computational time/cost, usually at least an order of magnitude, in comparison with one-dimensional simulations. This study presents a multi-fidelity Bayesian optimization, in which the machine learning model leverages low-fidelity (one-dimensional xRAGE) and high-fidelity (two-dimensional xRAGE) simulations to more accurately predict “pre-shot” target performance with respect to the expected experimental performance. By building a multi-fidelity Bayesian optimization framework coupled with xRAGE, the low-fidelity and high-fidelity simulations are able to inform one another, such that we have: (1) improved physics modeling in comparison with using low-fidelity simulations alone, (2) reduced computational time/cost in comparison with using high-fidelity simulations alone, and (3) more confidence in the expected performance of optimized targets during real-world experiments. In the future, we plan to use this robust multi-fidelity Bayesian optimization methodology to expedite the design of graded inner shells further and eventually full capsules as a part of the current double shell campaign at the National Ignition Facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Creation of a High-Yield AAV Vector Production Platform in Suspension Cells Using a Design-of-Experiment Approach

Recombinant adeno-associated virus (rAAV) vectors are a leading gene delivery platform, but vector manufacturing remains a challenge. New methods are needed to increase rAAV yields and reduce costs. Past efforts to improve rAAV production have focused on optimizing a single variable at a time, but this approach does not account for the interactions of multiple factors that contribute to vector generation. Here, we utilized a design-of-experiment (DOE) methodology to optimize rAAV production in a HEK293T suspension cell system. We simultaneously varied the transgene, packaging, and helper plasmid ratios, the total DNA concentration, and the cell density to systematically evaluate the impact of each variable across 52 conditions. The results revealed a unique set of parameters with a lower concentration of transgene plasmid, a higher concentration of packaging plasmid, and a higher cell density than previously described protocols. Using this DOE-optimized protocol, we achieved unpurified yields approaching 3 × 10 14 viral genomes (VGs)/L of cell culture. Additionally, we incorporated polyethylene glycol (PEG)-based virus precipitation, pH-mediated protein removal, and affinity chromatography to our downstream processing, enabling average purified yields of >1 × 10 14 VGs/L for rAAV-EGFPs across 13 serotypes and capsid variants.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Optimizing high energy density sulfur cathodes: A multivariate approach to electrode formulation and processing

Lithium-sulfur (Li-S) batteries involve complex solid-liquid-solid phase transformations during both discharging and charging processes, where cathode materials, formulation, and structure play a crucial role. Here, a design of experiments (DoE) methodology and an empirical model are developed to systematically explore the interactions and trade-offs among cathode factors and process variables, and to obtain generalizable effects estimates for the multivariate system. Compared to the conventional one-factor-at-a-time (OFAT) approach, this work demonstrates advantages in both efficiency and accuracy by allowing the data to guide future research and decisions. Further, an optimized cathode formulation and processing parameters are predicted and validated experimentally, achieving over 1000 mAh g -1 in discharge capacity and improved cycling under practical lean electrolyte (4 µL mg -1 S) and high S-loading cathodes (>4 mg cm -2 ) conditions. The optimized cathode was scaled up and assembled into Li-S pouch cells, achieving 316 Wh kg -1 in cell-level energy, proving that the comprehensive and rigorous framework for optimizing complex systems with DoE leads to improved performance in a practical pouch cell system.

25 ENERGY STORAGE↗
NASA NTRS1993

Integrated CFD modeling of gas turbine combustors

3D, curvilinear, multi-domain CFD analysis is becoming a valuable tool in gas turbine combustor design. Used as a supplement to experimental testing. CFD analysis can provide improved understanding of combustor aerodynamics and used to qualitatively assess new combustor designs. This paper discusses recent advancements in CFD combustor methodology, including the timely integration of the design (i.e. CAD) and analysis (i.e. CFD) processes. Allied Signal's F124 combustor was analyzed at maximum power conditions. The assumption of turbulence levels at the nozzle/swirler inlet was shown to be very important in the prediction of combustor exit temperatures. Predicted exit temperatures were compared to experimental rake data, and good overall agreement was seen. Exit radial temperature profiles were well predicted, while the predicted pattern factor was 25 percent higher than the harmonic-averaged experimental pattern factor.

Fuller, E. J.↗
NASA NTRS2003

Nuclear Electric Vehicle Optimization Toolset (NEVOT): Integrated System Design Using Genetic Algorithms

The Nuclear Electric Vehicle Optimization Toolset (NEVOT) optimizes the design of all major Nuclear Electric Propulsion (NEP) vehicle subsystems for a defined mission within constraints and optimization parameters chosen by a user. The tool uses a Genetic Algorithm (GA) search technique to combine subsystem designs and evaluate the fitness of the integrated design to fulfill a mission. The fitness of an individual is used within the GA to determine its probability of survival through successive generations in which the designs with low fitness are eliminated and replaced with combinations or mutations of designs with higher fitness. The program can find optimal solutions for different sets of fitness metrics without modification and can create and evaluate vehicle designs that might never be conceived of through traditional design techniques. It is anticipated that the flexible optimization methodology will expand present knowledge of the design trade-offs inherent in designing nuclear powered space vehicles and lead to improved NEP designs.

Tinker, Michael L.↗
NASA NTRS2004

Nuclear Electric Vehicle Optimization Toolset (NEVOT)

The Nuclear Electric Vehicle Optimization Toolset (NEVOT) optimizes the design of all major nuclear electric propulsion (NEP) vehicle subsystems for a defined mission within constraints and optimization parameters chosen by a user. The tool uses a genetic algorithm (GA) search technique to combine subsystem designs and evaluate the fitness of the integrated design to fulfill a mission. The fitness of an individual is used within the GA to determine its probability of survival through successive generations in which the designs with low fitness are eliminated and replaced with combinations or mutations of designs with higher fitness. The program can find optimal solutions for different sets of fitness metrics without modification and can create and evaluate vehicle designs that might never be considered through traditional design techniques. It is anticipated that the flexible optimization methodology will expand present knowledge of the design trade-offs inherent in designing nuclear powered space vehicles and lead to improved NEP designs.

Tinker, Michael L.↗
NASA NTRS1992

Propulsion system performance resulting from an Integrated Flight/Propulsion Control design

Propulsion system specific results are presented from the application of the Integrated Methodology for Propulsion and Airframe Control (IMPAC) design approach to Integrated Flight/Propulsion Control design for a STOVL aircraft in transition flight. The IMPAC method is briefly discussed and the propulsion system specifications for the integrated control design are examined. The structure of a linear engine controller that results from partitioning a linear centralized controller is discussed. The details of a nonlinear propulsion control system are presented, including a scheme to protect the engine operational limits: the fan surge margin and the acceleration/deceleration schedule which limits the fuel flow. Also, a simple but effective multivariable integrator windup protection scheme is investigated. Nonlinear closed-loop simulation results are presented for two typical pilot commands for transition flight: acceleration while maintaining flight path angle and a change in flight path angle while maintaining airspeed. The simulation nonlinearities include the airframe/engine coupling, the actuator and sensor dynamics and limits, the protection scheme for the engine operational limits, and the integrator windup protection. Satisfactory performance of the total airframe plus engine system for transition flight, as defined by the specifications, is maintained during the limit operation of the closed-loop engine subsystem.

Mattern, Duane↗
NASA NTRS1986

Management of SSME hardware life utilization

Statistical and probabilistic reliability methodologies were developed for the determination of hardware life limits for the Space Shuttle Main Engine (SSME). Both methodologies require that a mathematical reliability model of the engine (system) performance be developed as a function of the reliabilities of the components and parts. The system reliability model should be developed from the Failute Modes and Effects Analysis/Critical Items List. The statistical reliability methodology establishes hardware life limits directly from the failure distributions of the components and parts obtained from statistically-designed testing. The probabilistic reliability methodology establishes hardware life limits from a decision analysis methodology which incorporates the component/part reliabilities obtained from a probabilistic structural analysis, a calibrated maintenance program, inspection techniques, and fabrication procedures. Probilistic structural analysis is recommended as a tool to prioritize upgrading of the components and parts. The Weibull probability distribution is presently being investigated by NASA/MSFC to characterize the failure distribution of the SSME hardware from a limited data base of failures.

Pauschke, J. M.↗
NASA NTRS1999

Design of Composite Structures for Reliability and Damage Tolerance

A summary of research conducted during the first year is presented. The research objectives were sought by conducting two tasks: (1) investigation of probabilistic design techniques for reliability-based design of composite sandwich panels, and (2) examination of strain energy density failure criterion in conjunction with response surface methodology for global-local design of damage tolerant helicopter fuselage structures. This report primarily discusses the efforts surrounding the first task and provides a discussion of some preliminary work involving the second task.

Rais-Rohani, Masoud↗
NASA NTRS1990

Design optimization of gas generator hybrid propulsion boosters

A methodology used in support of a contract study for NASA/MSFC to optimize the design of gas generator hybrid propulsion booster for uprating the National Space Transportation System (NSTS) is presented. The objective was to compare alternative configurations for this booster approach, optimizing each candidate concept on different bases, in order to develop data for a trade table on which a final decision was based. The methodology is capable of processing a large number of independent and dependent variables, adjusting the overall subsystems characteristics to arrive at a best compromise integrated design to meet various specified optimization criteria subject to selected constraints. For each system considered, a detailed weight statement was generated along with preliminary cost and reliability estimates.

Weldon, Vincent↗
DOE OSTI2020

Urban building energy modeling (UBEM) tools: A state-of-the-art review of bottom-up physics-based approaches

Regulations corroborate the importance of retrofitting existing building stocks or constructing new energy-efficient districts. There is, thus, a need for modeling tools to evaluate energy scenarios to better manage and design cities, and numerous methodologies and tools have been developed. Among them, Urban Building Energy Modelling (UBEM) tools allow the energy simulation of buildings at large scales. Choosing an appropriate UBEM tool, balancing the level of complexity, accuracy, usability, and computing needs, remains a challenge for users. The review focuses on the main bottom-up physics-based UBEM tools, comparing them from a user-oriented perspective. Five categories are used: (i) the required inputs, (ii) the reported outputs, (iii) the exploited workflow, (iv) the applicability of each tool, and (v) the potential users. Moreover, a critical discussion is proposed, focusing on interests and trends in research and development. The results highlighted major differences between UBEM tools that must be considered to choose the proper one for an application. Finally, barriers of adoption of UBEM tools include the needs of a standardized ontology, a common three-dimensional city model, a standard procedure to collect data, and a standard set of test cases. This feeds into future development of UBEM tools to support cities’ sustainability goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

From minimum-viable-products to full models: a step-wise development of diagnostic forward models in support of design, analysis and modelling on the ST40 tokamak

Like most magnetic confined fusion experiments, the ST40 tokamak started off with a small subset of diagnostics and gradually increased the diagnostic set to include more complex and comprehensive systems. To make the most of each operational phase, forward models of various diagnostics are used and developed to aid design, provide consistency-checks during commissioning, test analysis methods, and build workflows to constrain high-level parameters to inform interpretation, theory and modelling. For new models and new analysis workflows, minimum-viable-products are released early, and their complexity is increased in a step-wise manner, facilitating the support of all programme phases on multiple parallel applications, while enabling learning opportunities and feedback loops. In this contribution we review the philosophy, scope and architecture of the framework under development. We discuss the details of some forward models, with examples on how they are used to aid diagnostic design, to investigate analysis methodologies through synthetic data, and how they are embedded in experimental analysis workflows. We compare previously published experimental results with new, more advanced analysis workflows employing more recent, detailed models and new diagnostic data, providing confirmation of the published material from the 2021–22 experimental campaign.

integrated data analysis↗
DOE OSTI2024

Multiport Converter based Auxiliary Power Supply for Heavy Duty Fuel Cell Power Train

This paper presents a multiport converter (MPC) based power supply to charge the 12 V and 24 V auxiliary batteries in heavy duty (HD) fuel cell (FC) electric vehicle (EV) power train. Compared to conventional auxiliary power supply architectures, the proposed architecture shares the power electronic components of the main power train yet preserves the isolation and all other desirable features of auxiliary power supplies. The proposed auxiliary power supply architecture reduces the requirements of the devices, gate drivers and thermal requirements thereby having potential benefits towards improving the power density, cost and weight of the overall power train. The topology, design parameters and control methodology are discussed, and results are presented to validate the proposed architecture.

Mukherjee, Subho↗
DOE OSTI2021

Manipulation and statistical analysis of the fluid flow of polymer semiconductor solutions during meniscus-guided coating

Recent work in structure–processing relationships of polymer semiconductors have demonstrated the versatility and control of thin-film microstructure offered by meniscusguided coating (MGC) techniques. Here, we analyze the qualitative and quantitative aspects of solution shearing, a model MGC method, using coating blades augmented with arrays of pillars. The pillars induce local regions of high strain rates—both shear and extensional—not otherwise possible with unmodified blades, and we use fluid mechanical simulations to model and study a variety of pillar spacings and densities. We then perform a statistical analysis of 130 simulation variables to find correlations with three dependent variables of interest: thin-film degree of crystallinity and transistor field-effect mobilities for charge-transport parallel (Μ para ) and perpendicular (Μ perp ) to the coating direction. Our study suggests that simple fluid mechanical models can reproduce substantive correlations between the induced fluid flow and important performance metrics, providing a methodology for optimizing blade design.

36 MATERIALS SCIENCE↗
DOE OSTI2020

On the Robustness of Network Community Structure Under Addition of Edges

Communities represent important functional modules in networked systems. A key goal in preserving such communities is understanding their robustness under perturbations. Previous research has studied the impact of node removals and edge removals on the community structure. However, the impact of edge additions on the robustness of the community structure is relatively unknown. Edge additions or false positive edges may simulate measurement errors or external exceptional events that threaten the functionality of networked systems. Here, we study the impact of edge additions on the community structure using Lancichinetti-Fortunato-Radicchi (LFR) benchmark networks. We show that, for a fixed network size, the impact of edge additions is greater on networks with initially weak community structure than on networks with strongly clustered structures. In addition, we find that the perception of the impact is also dependent on the community detection algorithm used to uncover communities. In particular, we found that modularity-based methods such as Leiden and Louvain are less affected than information-theoretic and message passing-based methods such as Infomap and Label Propagation. Our results demonstrate that edge addition can (a) significantly impact the community structure of networks based on their initial conditions, and (b) the perception of the impact is dependent on the community detection algorithm used. We describe limitations, open challenges, and how this methodology can inform the design of resilient networked systems under edge additions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Tunable electrochemical pathway for high-purity REMs and CMs

This report details a comprehensive research initiative focused on developing a technical research plan for the efficient and sustainable production of rare earth elements (REEs) and critical materials (CMs) from coal-based resources, specifically lignite coal from the Williston Basin in North Dakota. The project’s methodology centers on the design and evaluation of a tunable electrochemical pathway (TEP), an innovative approach aimed at achieving high-purity rare earth oxides (REOs), rare earth salts (RES), and CMs. This research is crucial for addressing the growing demand for these materials in clean energy technologies, electric vehicles, and high-tech applications, while reducing the United States’ reliance on foreign supply chains.

01 COAL, LIGNITE, AND PEAT↗