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DOE OSTI2024

End-Use Savings Shapes Measure Documentation: Heat Pump Rooftop Units With Exhaust Air Energy Recovery

This technical report documents the Advanced Rooftop Unit Control End Use Savings Shapes (EUSS) measure, including providing a description of the technology, modeling methods, and the energy savings calculated from applying the measure to applicable across the US commercial building stock using ComStock to quantify its potential. This measure replaces gas furnace and electric resistance rooftop units with high-efficiency variable speed heat pump rooftop units (HP-RTU) that include exhaust air heat or energy recovery. The measure uses the same assumptions and technology as the variable speed HP-RTU measure from EUSS 2023 release 1 but adds energy recovery to precondition outdoor ventilation air to reduce HVAC loads. The HP-RTU compressor lockout temperature is modeled as 0 degrees Fahrenheit; below this temperature, the heat pump is set to shut off. The unit is sized based on the design cooling loads, with backup electric resistance heating addressing any remaining loads including heating hours below the compressor lockout temperature when there is no heat pump heating.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Seismic Performance of Conventional and Additively Manufactured U-Shaped Flexural Plates

U-shape flexural plates (UFPs) have gained significant attention in seismic structural design due to their ability to provide stable hysteresis behaviour and serve as effective energy-dissipating devices. Concurrently, Additive Manufacturing (AM) has advanced significantly, enabling the production of metallic components with mechanical properties comparable to those of conventionally manufactured cold-rolled materials. This study aims to explore the seismic response of single and double UFP fabricated through Laser Powder Based Fusion (LPBF) and conventional cold rolled 316L stainless steel (SS). The experimental results are evaluated based on force-displacement hysteresis behaviour, energy dissipation capacity, load-carrying capacity, and stiffness degradation. The findings confirm the efficacy of AM-fabricated UFPs for seismic energy dissipation. Additionally, the results suggest the potential for further improvement through the optimization of AM process parameters, such as laser scan speed, hatch spacing, and layer thickness, to enhance hysteretic performance and energy dissipation characteristics.

Risal, Kshitiz [Idaho State University]↗

NASA NTRS1990

Evaluation of finite-element models and stress-intensity factors for surface cracks emanating from stress concentrations

A re-evaluation of the 3-D finite-element models and methods used to analyze surface crack at stress concentrations is presented. Previous finite-element models used by Raju and Newman for surface and corner cracks at holes were shown to have ill-shaped elements at the intersection of the hole and crack boundaries. Improved models, without these ill-shaped elements, were developed for a surface crack at a circular hole and at a semi-circular edge notch. Stress-intensity factors were calculated by both the nodal-force and virtual-crack-closure methods. Comparisons made between the previously developed stress-intensity factor equations and the results from the improved models agreed well except for configurations with large notch-radii-to-plate-thickness ratios. Stress-intensity factors for a semi-elliptical surface crack located at the center of a semi-circular edge notch in a plate subjected to remote tensile loadings were calculated using the improved models.

Tan, P. W.↗

NASA NTRS2005

The Influence of Roughness on Gear Surface Fatigue

Gear working surfaces are subjected to repeated rolling and sliding contacts, and often designs require loads sufficient to cause eventual fatigue of the surface. This research provides experimental data and analytical tools to further the understanding of the causal relationship of gear surface roughness to surface fatigue. The research included evaluations and developments of statistical tools for gear fatigue data, experimental evaluation of the surface fatigue lives of superfinished gears with a near-mirror quality, and evaluations of the experiments by analytical methods and surface inspections. Alternative statistical methods were evaluated using Monte Carlo studies leading to a final recommendation to describe gear fatigue data using a Weibull distribution, maximum likelihood estimates of shape and scale parameters, and a presumed zero-valued location parameter. A new method was developed for comparing two datasets by extending the current methods of likelihood-ratio based statistics. The surface fatigue lives of superfinished gears were evaluated by carefully controlled experiments, and it is shown conclusively that superfinishing of gears can provide for significantly greater lives relative to ground gears. The measured life improvement was approximately a factor of five. To assist with application of this finding to products, the experimental condition was evaluated. The fatigue life results were expressed in terms of specific film thickness and shown to be consistent with bearing data. Elastohydrodynamic and stress analyses were completed to relate the stress condition to fatigue. Smooth-surface models do not adequately explain the improved fatigue lives. Based on analyses using a rough surface model, it is concluded that the improved fatigue lives of superfinished gears is due to a reduced rate of near-surface micropitting fatigue processes, not due to any reduced rate of spalling (sub-surface) fatigue processes. To complete the evaluations, surface inspection were completed. The surface topographies of the ground gears changed substantially due to running, but the topographies of the superfinished gears were essentially unchanged with running.

Krantz, Timothy↗

NASA NTRS1982

Extensional collapse modes of structural members

Attenuation of the load transmitted to a vehicle occupant by the structure, either by modifying structural assembly, changing geometry of its elements, or adding specific load limiting devices to help dissipate kinetic energy was studied. General aviation aircraft have fuselage subfloors of a built up structure which are generally very stiff perpendicular to the floor of the cabin. The subfloor structure, designed to crush at an appropriate force level, can be used to advantage in a crash by dissipating energy through plastic buckling of the floor beams and frames. Simple closed form solutions to predict the mean crushing force levels of subfloor designs is useful in engineering practice. The crushing process of thin walled, plate formed, open structures with particular emphasis on L and cruciform shapes was analyzed. Lower and upper bound solutions for the mean crushing strength of cruciforms are obtained by considering modes of deformation which account for both bending and extensional deformation. It is the importance of extensional deformation to the energy absorption process, representing at least one third of the dissipated energy is shown.

Hayduk, R. J.↗

NASA NTRS1984

Extensional collapse modes of structural members

Hayduk, R. J.↗

NASA NTRS1989

Nonlinear and snap-through responses of curved panels to intense acoustic excitation

Assuming a single-mode transverse displacement, a simple formula is derived for the transverse load-displacement relationship of a plate under in-plane compression. The formula is used to derive a simple analytical expression for the nonlinear dynamic response of postbuckled plates under sinusoidal or random excitation. The highly nonlinear motion of snap-through can be easily interpreted using the single-mode formula. Experimental results are obtained with buckled and cylindrical aluminum panels using discrete frequency and broadband excitation of mechanical and acoustic forces. Some important effects of the snap-through motion on the dynamic response of the postbuckled plates are described. Static tests were used to identify the deformation shape during snap-through.

Ng, C. F.↗

NASA NTRS2005

Predicting Flows of Rarefied Gases

DSMC Analysis Code (DAC) is a flexible, highly automated, easy-to-use computer program for predicting flows of rarefied gases -- especially flows of upper-atmospheric, propulsion, and vented gases impinging on spacecraft surfaces. DAC implements the direct simulation Monte Carlo (DSMC) method, which is widely recognized as standard for simulating flows at densities so low that the continuum-based equations of computational fluid dynamics are invalid. DAC enables users to model complex surface shapes and boundary conditions quickly and easily. The discretization of a flow field into computational grids is automated, thereby relieving the user of a traditionally time-consuming task while ensuring (1) appropriate refinement of grids throughout the computational domain, (2) determination of optimal settings for temporal discretization and other simulation parameters, and (3) satisfaction of the fundamental constraints of the method. In so doing, DAC ensures an accurate and efficient simulation. In addition, DAC can utilize parallel processing to reduce computation time. The domain decomposition needed for parallel processing is completely automated, and the software employs a dynamic load-balancing mechanism to ensure optimal parallel efficiency throughout the simulation.

LeBeau, Gerald J.↗

NASA NTRS2019

Common Probe Design Study and Follow-On Activities

The Common Probe Study was funded by the NASA's Planetary Science Division in the Science Mission Directorate in 2018 to investigate the feasibility of a common aeroshell design for atmospheric probe missions at Venus, Jupiter, Saturn, Uranus, and Neptune. The study involved 4 NASA Centers: Ames Research Center, Goddard Space Flight Center, Langley Research Center, and the Jet Propulsion Laboratory. The common aeroshell design that was studied was a 400 kg, 1.5 m diameter, 45-degree sphere cone shape with a high density heatshield material (Heatshield for Extreme Entry Environments Technology, or HEEET) and a parachute system to extract the descent vehicle. This size of aeroshell could accommodate a descent vehicle of 0.75 m diameter, which could encompass both Tier 1 and Tier 2 science instruments at each of the 5 destinations. Study methodology: First, a notional payload of instruments for each destination was defined based on the top priority measurements indicated by the Planetary Science Decadal Survey. Steep and shallow entry flight path angles (EFPA) were defined for each planet based on qualification and operational g-load limits for current, state-of-the-art instruments. Interplanetary trajectories were then identified that bounded the EFPA range.Next, 3-DoF simulations for entry trajectories were run using the entry state vectors from the interplanetary trajectories. Conical ribbon parachutes were sized based on heatshield separation dynamics. Aero-heating correlations were used to generate stagnation point convective and radiative heat flux profiles. High fidelity thermal response models for various TPS materials were used to size stagnation point thicknesses, with margins based on previous studies. Backshell TPS masses were assumed based on scaled heat fluxes from the heatshield and also from previous mission concepts.Based on these analyses, we have found that the common design is applicable for atmospheric probe missions for 4 out of the 5 destinations. Because of the unique gravity well for Jupiter, the entry environments are more severe resulting in heat loads an order of magnitude higher than for the other destinations.The next step is to determine what follow-on activities NASA should engage in. A questionnaire for the atmospheric probe community has been developed, with a focus on what size of aeroshell should be further analyzed (smaller or same diameter), and what incentives would make using such an aeroshell, if assembled and available, desirable to mission proposers.Preliminary results from this questionnaire will be presented.

Hwang, Helen H.↗

DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1997

Aerothermal Performance Constraints for Small Radius Leading Edges Operating at Hypervelocity

Small radius leading edges and nosetips were used to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating blunted the available thermal protection system materials. Recent studies indicate that ultra-high temperature composite (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp leading edge components in the near future. Steady-state aerothermal performance constraints for UHTC components are presented in this paper to identify their non-ablating operational capability at altitudes from sea level to 90 km. An integrated design tool was developed to estimate these constraints. The tool couples aerothermodynamic heating with material response using commercial finite element analysis software and is capable of both steady-state and transient analysis. Performance during entry is analyzed by transient thermal analysis along the trajectory. The thermal load condition from the transient thermal analysis is used to estimate thermal stress. Applying the tool to UHTC materials shows that steady-state, non-ablating operation of a HfB2/SiC(A-7) (A-7) component is possible at velocities approaching Earth's circular orbital velocity of 7.9 km/s at altitudes approaching 70 km.

Kolodziej, Paul↗

NASA NTRS2024

Modeling Dynamic Crush Behavior of Carbon Fiber Reinforced Polymer Composite Structures Using MAT213

Modeling crushing of carbon fiber reinforced polymer (CFRP) composites is challenging, and current simulation methodologies involve tuning of non-physical parameters. MAT213, a next-generation material model, has advanced functionality to better simulate dynamic impact loading. The objective of the present investigation is to evaluate the potential for using MAT213 to simulate dynamic crushing of CFRPs. Two sets of simulations were performed: one for calibration based on a set of coupon-level experiments and another for prediction of the response of structural elements. Simulations involving dynamic crushing of flat specimens were iteratively run to calibrate model parameters. The calibration demonstrated that MAT213 could produce a simulated force-displacement response within experimental scatter. The simulated failure morphology was also comparable to the experiments. After successful calibration, predictive simulations of dynamic crushing of C-channel shaped specimens were completed using a simulated crash sled test rig and two pairs of impactor mass/velocity conditions. The simulated force-displacement curve in the crash sled simulations for the lower-velocity condition fell within the experimental scatter, but the stable crush force was underpredicted by 27% in the higher-velocity simulations. Better correlation in the lower-velocity test condition likely results from the calibration condition being a similar velocity to the lower-velocity crash sled condition.

Dynamic Crush↗

DOE OSTI2023

Direct Numerical Simulation of Flame-Wall Interaction for Low-Carbon Gas Turbine Combustion

Green hydrogen (H2) and ammonia (NH3) are emerging as carbon free alternatives to hydrocarbon fuels. In gas turbines, flames interact with the combustor liner (wall), which affects the pollutant emissions, the burning efficiency, and the thermal load on the liner. We lack understanding of this important flame-wall interaction (FWI) for alternative fuels. FWI occurs at the scale of the flame thickness, and such scales are only resolved by direct numerical simulation. Here, we resolve the FWI for NH3 and H2 flames. Preliminary results of two distinct projects are presented: 2D laminar anchored V-flame, and 3D turbulent swirling flame. For the laminar flame, we show flame quenching at the wall and resulting leakage of NH3 and increased N2O, but decreased NO emissions. For the swirling flame, we show CO emissions, and comparison of flame shapes and location to experimental measurements. Ultimately we show that quenching and pollutant emissions strongly affected by fuel/air ratio, and that an inclined wall can stabilize very lean turbulent CH4/H2 flames, but prone to large CO emissions.

adaptive mesh refinement↗

DOE OSTI2026

A wide-range thermodynamically consistent constitutive model for dynamic loading of partially saturated porous media

SUMMARY This paper presents a novel thermodynamically consistent constitutive model for partially saturated porous rocks across a wide range of conditions. The material states generated behind the shock wave from an explosive source can vary significantly, ranging from crushed and melted rock near the source to a poroelastic medium in the far field. In the model, rock strength is determined by the effective pressure, which is calculated using two independent equations of state: one for the solid rock and another for the pore fluid. The model accounts for shock-induced liquefaction resulting from fluid pressure buildup in the pore spaces near the explosive source. Simultaneously, it describes the increase in wave propagation speed due to elastic pore contraction in both dry and partially saturated rocks. This model is applied to investigate how fluid saturation affects the amplitude and shape of the generated waves, as well as the residual stress surrounding the cavity formed by spherical explosions.

Vorobiev, Oleg [Lawrence Livermore National Labora↗

DOE OSTI2022

Observations on the deformation of metal microspheres in shock-driven polymer flows

We report that solid particles can be fragmented by a fast-moving fluid if their velocity difference is great enough, such as during the atmospheric entry of meteoroids or the shock compression of engineered particulate composites. The extent of particle deformation and breakup in such systems is poorly understood because the necessary extreme conditions make observation difficult and data scarce. To meet this need, experiments combining ultrafast synchrotron-based radiography with plate impact loading were performed at the dynamic compression sector at the advanced photon source. Metal microspheres of several densities and strengths (Au, Ta, and W) were placed inside a polymer matrix. A planar shock wave was then produced in the polymer by the impact of a gun-launched flyer plate. X-ray images of the resulting flow were collected at ~150ns intervals. These images document the progression of particle deformation across a range of flow conditions and particle materials. They show that the extent of deformation is sensitive to the ratio of drag stress to particle strength. The deforming particle's shape is determined by the initial shock–particle interaction, fluid stagnation pressure, and vorticity, each acting on its own timescale. A set of scaling relationships is presented to capture these observations and enable comparison with prior hydrodynamic data. The result is a framework for predicting the conditions under which strong particles are severely deformed by a shock-driven flow.

36 MATERIALS SCIENCE↗

NASA NTRS2009

Multi-Modulator for Bandwidth-Efficient Communication

A modulator circuit board has recently been developed to be used in conjunction with a vector modulator to generate any of a large number of modulations for bandwidth-efficient radio transmission of digital data signals at rates than can exceed 100 Mb/s. The modulations include quadrature phaseshift keying (QPSK), offset quadrature phase-shift keying (OQPSK), Gaussian minimum-shift keying (GMSK), and octonary phase-shift keying (8PSK) with square-root raised-cosine pulse shaping. The figure is a greatly simplified block diagram showing the relationship between the modulator board and the rest of the transmitter. The role of the modulator board is to encode the incoming data stream and to shape the resulting pulses, which are fed as inputs to the vector modulator. The combination of encoding and pulse shaping in a given application is chosen to maximize the bandwidth efficiency. The modulator board includes gallium arsenide serial-to-parallel converters at its input end. A complementary metal oxide/semiconductor (CMOS) field-programmable gate array (FPGA) performs the coding and modulation computations and utilizes parallel processing in doing so. The results of the parallel computation are combined and converted to pulse waveforms by use of gallium arsenide parallel-to-serial converters integrated with digital-to-analog converters. Without changing the hardware, one can configure the modulator to produce any of the designed combinations of coding and modulation by loading the appropriate bit configuration file into the FPGA.

Gray, Andrew↗

NASA NTRS2018

The Effect of Thin Film Adhesives on Mode I Interlaminar Fracture Toughness in Carbon Fiber Composites with Shape Memory Alloy Inserts

Shape Memory Alloy (SMA) was placed within Polymer Matrix Composite (PMC) panels alongside film adhesives to examine bonding. Double cantilever beam (DCB) testing was performed using ASTM D5528. C-scanning was performed before testing, modal acoustic emissions (MAE) were monitored during testing, and microscopy performed post-test. Data was analyzed using modified beam theory (MBT), compliance calibration (CC) and modified compliance calibration (MCC) methods. Fracture toughness for control specimens was higher than previously reported due to fiber-bridging. Specimens with SMAs and adhesives stabilized crack propagation. Results revealed SMA-bridging; a phenomenon mimicking fiber-bridging which increased the load and fracture toughness of SMA specimens.

Derek J Quade↗

NASA NTRS2006

Reconfigurable Software for Controlling Formation Flying

Software for a system to control the trajectories of multiple spacecraft flying in formation is being developed to reflect underlying concepts of (1) a decentralized approach to guidance and control and (2) reconfigurability of the control system, including reconfigurability of the software and of control laws. The software is organized as a modular network of software tasks. The computational load for both determining relative trajectories and planning maneuvers is shared equally among all spacecraft in a cluster. The flexibility and robustness of the software are apparent in the fact that tasks can be added, removed, or replaced during flight. In a computational simulation of a representative formation-flying scenario, it was demonstrated that the following are among the services performed by the software: Uploading of commands from a ground station and distribution of the commands among the spacecraft, Autonomous initiation and reconfiguration of formations, Autonomous formation of teams through negotiations among the spacecraft, Working out details of high-level commands (e.g., shapes and sizes of geometrically complex formations), Implementation of a distributed guidance law providing autonomous optimization and assignment of target states, and Implementation of a decentralized, fuel-optimal, impulsive control law for planning maneuvers.

Mueller, Joseph B.↗