Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “THERMAL STRESSES”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,711 records · Page 95
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Ensemble Learning, Prediction and Li-Ion Cell Charging Cycle Divergence

In recent years, the pervasive use of lithium ion (Li-ion) batteries in applications such as cell phones, laptop computers, electric vehicles, and grid energy storage systems has prompted the development of specialized battery management systems (BMS). The primary goal of a BMS is to maintain a reliable and safe battery power source while maximizing the calendar life and performance of the cells. To maintain safe operation, a BMS should be programmed to minimize degradation and prevent damage to a Li-ion cell, which can lead to thermal runaway. Cell damage can occur over time if a BMS is not properly configured to avoid overcharging and discharging. To prevent cell damage, efficient and accurate cell charging cycle characteristics algorithms must be employed. In this paper, computationally efficient and accurate ensemble learning algorithms capable of detecting Li-ion cell charging irregularities are described. Additionally, it is shown using machine and deep learning that it is possible to accurately and efficiently detect when a cell has experienced thermal and electrical stress due to cell overcharging by measuring charging cycle divergence.

25 ENERGY STORAGE↗
DOE OSTI2021

Computational Modeling of Photovoltaic Mini-Modules Undergoing Accelerated Stress Testing

A finite element model of a four-cell photovoltaic mini-module was developed and compared to experimental results from an accelerated stress test protocol in order to validate that computational models can accurately represent their physical counterparts when subjected to mechanical loading and to assess mini-module representativeness against full scale photovoltaic modules. Deflected shapes across the simulated mini-modules were compared to measured mini-module shapes when subjected to various pressure loads. Displaced mini-module shape results constrained to the experimental protocols of 0.4 mm and 1.1 mm of displacement at the mini-module center were compared to experimental results of full-size modules subjected to module qualification test load levels of 1.0 kPa and 2.4 kPa, to assess if the bending of mini-modules was representative of full-sized modules under the load. Temperature cycling was incorporated into the model to simulate the impacts of stress due to thermal expansion of the backsheet and cells. A preliminary uncertainty analysis was performed to show how variations in material properties and geometric parameters change the simulation results.

computational modeling↗
DOE OSTI2021

UV-Fluorescence Imaging of Silicon PV Modules After Outdoor Aging and Accelerated Stress Testing

Fast, non-destructive, outdoor-compatible methods for photovoltaic module characterization are essential for monitoring module quality without disrupting energy production. UV-fluorescence (UVF) imaging of the encapsulant layer can be used for crack detection in the field. We show that UVF patterns vary widely between modules and types of applied stress. We propose that combining accelerated stress testing (e.g. thermal cycling and damp heat) with field investigations can help build understanding of different types of UVF, which are formed and subsequently quenched at varying rates. Ultimately, such understanding could enable estimating when cracks were formed.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2019

Bond Wire Damage Detection and SOH Estimation of a Dual Pack IGBT Power Module using Active Power Cycling and Reflectometry

High thermal and electrical stress, over a period of time tends to cause deterioration of the health of power electronic switches. A huge fraction of research efforts involves the study of power electronic device reliability and development of novel techniques with higher accuracy in health estimation of such devices. Until today, no other existing techniques can determine the number of lifted bond wires and their locations in a live IGBT module. Through this paper, a new method for online condition monitoring of IGBTs and IGBT modules using SSTDR has been proposed. Unlike traditional methods, this research work concentrates at the gate terminals of the device instead of looking at the collector side. In addition, the RL-equivalent circuit to represent a bond wire has been developed for the DUT and simulated in CST Studio Suite to measure the reflection amplitudes. Both the experimental and simulation results have been compared. These results prove that a single measurement is sufficient to predict the failure of the device instead of looking at the traditional precursor parameter. With only two sets of measurements, it is possible to locate the aged device inside a module and detect the number of bond wire lift offs associated to that device.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Vibrational spectroscopy analysis of silica and silicate glass networks

Vibrational spectroscopy has been widely used to investigate various structural aspects of the glass network, and there are a plethora of papers reporting subtle but consistent changes in infrared and Raman spectral features of glass upon alterations of glass compositions, thermal histories, mechanical stresses, or surface treatments. However, interpretations of such spectral features are still obscured due to the lack of well-established physical principles accurately describing vibrational modes of the non-crystalline glass network. Due to the non-equilibrium nature of the glass network, three-dimensionally connected without any long-range orders, vibrational spectral features of glass cannot be interpreted using the analogy with those of isolated molecular moieties or crystalline counterparts. Here, this feature article explains why such comparisons are outdated and describes the recent advances made from theoretical calculations of vibrational spectral features of amorphous networks or comparisons of computational results with experimental data. For the interpretation of vibrational spectral features of silica and silicate glasses, the following empirical relationships are suggested: (i) the intensity-weighted peak position of the Si-O-Si stretch mode negatively correlates with the weighted average of the Si-O bond length distribution, and (ii) the broad band of the Si-O-Si bending mode negatively correlates with the Si-O-Si bond angle distribution. Selected examples of vibrational spectroscopic imaging of surface defects are discussed to deliberate the implication of these findings in the structure-property relationship of silica and silicate glass materials. Unanswered questions and continuing research challenges are identified.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

Engineering↗
DOE OSTI2021

Seismic fault weakening via CO 2 pressurization enhanced by mechanical deformation of dolomite fault gouges

Carbon dioxide emissions from dolomite decarbonation play an essential role in the weakening of carbonate faults by lowering the effective normal stress, which is thermally activated at temperatures above 600–700 °C. However, the mechanochemical effect of low-crystalline ultrafine fault gouge on the decarbonation and slip behavior of dolomite-bearing faults remains unclear. In this study, we obtained a series of artificial dolomite fault gouges with systematically varying particle sizes and dolomite crystallinities using a high-energy ball mill. The laboratory-scale pulverization of dolomite yielded MgO at temperatures below 50 °C, indicating that mechanical decarbonation without significant heating occurred due to the collapse of the crystalline structure, as revealed by X-ray diffraction and solid-state nuclear magnetic resonance results. Furthermore, the onset temperature of thermal decarbonation decreased to ~400 °C. Numerical modeling reproduced this two-stage decarbonation, where the pore pressure increased due to low-temperature thermal decarbonation, leading to slip weakening on the fault plane even at 400–500 °C; i.e., 200–300 °C lower than previously reported temperatures. Thus, the presence of small amounts of low-crystalline dolomite in a fault plane may lead to a severely reduced shear strength due to thermal decomposition at ~400 °C with a small slip weakening distance.

58 GEOSCIENCES↗
DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗
DOE OSTI2012

Warm Bias and Parameterization of Boundary Upwelling in Ocean Models

It has been demonstrated that Eastern Boundary Currents (EBC) are a baroclinic intensification of the interior circulation of the ocean due to the emergence of mesoscale eddies in response to the sharp buoyancy gradients driven by the wind-stress and the thermal surface forcing. The eddies accomplish the heat and salt transport necessary to insure that the subsurface flow is adiabatic, compensating for the heat and salt transport effected by the mean currents. The EBC thus generated occurs on a cross-shore scale of order 20-100 km, and thus this scale needs to be resolved in climate models in order to capture the meridional transport by the EBC. Our result indicate that changes in the near shore currents on the oceanic eastern boundaries are linked not just to local forcing, such as coastal changes in the winds, but depend on the basin-wide circulation as well.

58 GEOSCIENCES↗
DOE OSTI2016

Studies of Heavy-Ion Reactions and Transuranic Nuclei

Studies of heavy-ion reactions and transuranic nuclei performed by the University of Rochester Nuclear Science Research Group have been successful in furthering experimental systematics and theoretical understanding of the behavior of nuclear systems excited to their limits of stability. The theoretical results explain specifically the “boiling” and “vaporization” of atomic nuclei, but are more generally applicable to isolated, quantal many-particle systems which, under thermal or mechanical stresses, all disintegrate by evaporation, via surface cluster emission, or via fission-like processes. Accompanying experimental investigations by the group have demonstrated several new types of dynamical instability of nuclei: In central, “head-on” collisions, target nuclei exhibit limited ability to stop energetic projectile nuclei and to dissipate the imparted linear momentum. Substantial matter overlap (“neck”) between projectile and target nuclei, which is observed at elevated collision energies, can be stretched considerably and break at several places simultaneously. These results provide new testing grounds for microscopic theory of the cohesion of nuclear matter. This property has remained elusive, even though the elementary nucleon-nucleon forces are well known since some time. Technical R&D has resulted in a detailed characterization of a novel plastic material, which can now be used in the design of sensitive diagnostic systems for various types of radio-activity. Innovative application of powerful laser systems has produced intense, controllable sources of exotic particle radioactivity for nuclear investigations. Several students have received their Ph.D. degree in experimental nuclear science for their work on basic nuclear research or R&D projects.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2018

Probability Distributions for Effective Permeability of Potentially Leaking Wells at CO 2 Sequestration Sites

Wells with defects originating from either poor completions or subsequent damage arising from chemical, thermal and/or mechanical stresses provide potential pathways for leakage of carbon dioxide (CO 2 ) and brine from a CO 2 sequestration site. This report provides a methodology for analyzing data on the frequency of occurrence of defective wells and the effective permeability of the damaged wells. The results include bimodal, log-normal distributions of the effective permeability of wells in addition to other distributions designed to provide a measure of the likelihood of encountering a leaking well in a CO 2 storage project.

58 GEOSCIENCES↗
DOE OSTI2018

Precursor-Derived Nanostructured Silicon Carbide Based Materials for Magnetohydrodynamic Electrode Applications

Development of suitable materials for use in the MHD generator is one of the most challenging tasks. Extremely high temperatures coupled with highly corrosive seed-laden atmosphere limit choice of the materials in contact with the high temperature plasma to just a few materials. These materials are simultaneously subjected to stresses of mechanical, thermal, chemical, electrical and high temperature-electicalmagnetic nature. In this work, novel class of SiC based ceramic composite materials with tailored compositions through a polymer precursor derived synthesis route was developed. SiC has a strong covalent bonding character, resulting in high values of mechanical strength, high hardness and chemical stability while retaining good electrical properties at elevated temperatures. A unique feature of the precursor-derived materials was the presence of nanostructured crystalline SiC domains separated by nanoscale carbon which made these materials excellent candidates for the electrodes that withstands at extremely high temperatures while maintaining good mechanical and electrical properties.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Precursor-Derived Nanostructured Silicon Carbide Based Materials for Magnetohydrodynamic Electrode Applications

Development of suitable materials for use in a magneto-hydro-dynamic (MHD) generator is a challenging task. Extremely high temperatures coupled with highly corrosive seed-laden atmosphere limit the choice of materials in contact with the high temperature plasma to just a few materials. These materials are simultaneously subjected to stresses of mechanical, thermal, chemical, electrical and high temperature-electromagnetic nature. In this work, a novel class of silicon carbide (SiC) based ceramic composite materials with compositions tailored through a polymer precursor derived synthesis route was developed. SiC has a strong covalent bonding character, resulting in high values of mechanical strength, high hardness and chemical stability while retaining good electrical properties at elevated temperatures. Since a unique feature of the precursor-derived materials was the presence of crystalline SiC domains separated by nanoscale carbon, feasibility of materials for electrodes that need to withstand at extremely high temperatures while maintaining good mechanical and electrical properties was investigated.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Assembly of Capsules for Irradiation of Silicon Carbide Joint Specimens in the High Flux Isotope Reactor

This report provides a summary of the test matrix and assembly of thirteen capsules containing silicon carbide joint specimens, where the goal of this experiment is to investigate the effects of irradiation on such joints. Two capsule designs are used to accommodate two different specimen geometries: a small torsion specimen to measure basic thermomechanical properties, and a cladding-style “end plug” specimen to demonstrate the strength and integrity of such cladding under typical thermal gradients and stresses. The assembled capsules are scheduled for two cycles of irradiation in the flux trap of the High Flux Isotope Reactor with two different target temperatures: 350 and 750°C.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of Electro-chemical Battery Model for Plug-and-Play Eco-system Library

Energy storage components are fundamental to the concept of an Integrated Energy System (IES). They serve to store surplus energy during low-demand periods for later release when other IES components (i.e., Secondary Energy Source, Balance of Plant, etc.) would otherwise have to operate flexibly. This provision for storage avoids high-amplitude power ramps in these components thereby limiting thermal and mechanical stresses to their internals and providing for extended service life. This report describes a dynamic model that has been developed for an electrochemical battery. The lithium-ion (Li-ion) cell was selected as representative technology. The battery model was developed in the Dymola simulation environment and meets the requirements of the ecosystem plug-and-play library. The model accurately describes the electric dynamic response of a Li-ion battery for an imposed charging/discharging power profile. The corresponding physical limitations related to over-power scenarios, and the impact of the residual state of charge are accounted for in the model. A literature review of the major degradation processes affecting Li-ion batteries was performed. Given the purposes of the CTD-IES project, the progressive fade of the installed capacity, the reduction of the round-trip efficiency, and the limits on the number of charging/discharging cycles are aspects that need to be taken into account in techno-economic analyses. The modeling of these degradation phenomena becomes crucial when predictions over long time horizons (capacity expansion) are made. For each one of these phenomena, a brief description is given, and some figures to be implemented in the HERON optimization algorithm are presented.

25 ENERGY STORAGE↗
DOE OSTI2023

Machine-Learned Structure-Property Relationship in Metallic Glasses (Final Report)

The goal of the proposed work was to gain the ability to predict properties from the known coordinates (relative positions) of atoms in a metallic glass, presuming that information about which regions of the glass are fertile for rearrangment (defects) are encoded in this structural information. This goal is important to the science of metallic glasses. This research of applied machine learning methods to automate the development of a relationship between structural measures and thermally and stress-activated events in the metallic glass. In this way, the work aimed to building a bridge between structure and properties for this class of materials. The work is expected to have timely impact on guiding the tuning of internal structures of metallic glasses for desired properties. It also represents an advance in applying machine learning techniques to discerning the properties of materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Salt Tank Testbed: a Test Site Designed to Replicate Floor Buckles Observed in Commercial TES Tanks

A test site has been designed and is under construction to replicate the buckling failure ob-served in several in-service storage tanks for nitrate salts operating up to 565°C. In commercial tanks multiple factors have been identified that influence the floors susceptibility to buck-ling, including: the as-manufactured shape of the floor, high compressive stresses due to thermal gradients and/or friction, fluid inventory and absolute temperature. Based on exten-sive modeling analysis it was determined that similar buckles can be reproduced in a scaled test tank (approximately 9x smaller than a representative commercial tank design). To buckle the scaled tank a radial thermal gradient is generated in the tank with a low fluid level, the fluid level is then increased while maintaining the thermal gradient; based on the modeling results just one of these cycles can plastically deform the tank floor. The test site which is under construction is designed to replicate this damaging cycle at lower temperatures. The goal of testing will be to reproduce this damaging cycle and buckle the scaled test tank floor, allowing proper model validation and a methodology for comparing different tank designs at a smaller (and less costly) scale.

25 ENERGY STORAGE↗
DOE OSTI2023

Repairing High γ’ Hot Section Gas Turbine Components Using Advanced Manufacturing

This article describes the ability to use laser-blown powder deposition to repair high γ' IN-100 superalloy gas turbine components. The influence of various process conditions on the ability to make crack-free IN-100 deposits over surrogate high γ' alloys was investigated to identify cracking mechanisms in the deposit and heat-affected zones (HAZs). The various crack formation mechanisms, such as solidification cracking and liquation cracking, were evaluated using multiscale characterization and numerical simulation. The cracking in the deposit region was predominantly solidification cracking, while those observed in the HAZ were liquation cracking. The results showed that controlling thermally induced residual stresses is the key to eliminating cracking, and the optimum preheat temperature was determined. In conclusion, the results were then contrasted with those in published literature and an approach to effectively repair hot section parts was presented.

36 MATERIALS SCIENCE↗