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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗
NASA NTRSDate not supplied

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗
NASA NTRS1959

Propellant Vaporization as a Criterion for Rocket-Engine Design; Experimental Performance, Vaporization and Heat-Transfer Rates with Various Propellant Combinations

Experimental combustion efficiencies of eleven propellant combinations were determined as a function of chamber length. Efficiencies were measured in terms of characteristic exhaust velocities at three chamber lengths and in terms of gas velocities. The data were obtained in a nominal 200-pound-thrust rocket engine. Injector and engine configurations were kept essentially the same to allow comparison of the performance. The data, except for those on hydrazine and ammonia-fluorine, agreed with predicted results based on the assumption that vaporization of the propellants determines the rate of combustion. Decomposition in the liquid phase may be.responsible for the anomalous behavior of hydrazine. Over-all heat-transfer rates were also measured for each combination. These rates were close to the values predicted by standard heat-transfer calculations except for the combinations using ammonia.

Clark, Bruce J.↗
NASA NTRS1989

Analysis of whisker-toughened ceramic components: A design engineer's viewpoint

The use of ceramics components in gas turbines, cutting tools, and heat exchangers has been limited by the relatively low flaw tolerance of monolithic ceramics. The development of whisker toughened ceramic composites offers the potential for considerable improvement in fracture toughness as well as strength. However, the variability of strength is still too high for the application of deterministic design approaches. Several phenomenological reliability theories proposed for this material system are reviewed and the development is reported of a public domain computer algorithm. This algorithm, when coupled with a general purpose finite element program, predicts the fast fracture reliability of a structural component under multiaxial loading conditions.

Duffy, Stephen F.↗
DOE OSTI2025

ORNL Design Engineering Library: Validated Thermoelectric Digital Twins

Radioisotope thermoelectric generators (RTGs) serve a crucial role in supplying thermal and electrical energy for reliable and long-duration power in remote and extreme environments. The thermal energy is provided by the decay of radioisotopes and is converted into electrical energy using the steady-state thermoelectric process by exploiting the Seebeck effect. Maintaining a thermal gradient through the material is necessary to drive current production. Modern predictive multi-physics tools are able to effectively describe the complex and strongly coupled phenomena needed for accurate model-based system engineering efforts needed to develop higher performing RTGs. Experimental validation of model simulations is essential to confirm the accuracy, reliability, and applicability of predictive multiphysics tools. Validation fosters confidence among users, helps meet regulatory requirements, and contributes to the ongoing improvement of simulation techniques, ultimately leading to better, safer, and more efficient designs and processes. Validated models can then be used as digital twins and can be interrogated to understand and quantify the performance gaps between theoretical and physical systems. These insights can be used to build higher performing systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Engineering Design Report: High-Pressure Safety Squib

This project encompassed the mechanical portion of the squib system and included the design and analysis of the valve body, selection of tube and tube fittings, valve mounting, and initiator/detonator selection. The electrical portion of the squib has already been designed by another team and is outside of the scope of the project. Electrical information and requirements provided are only for use in selecting a compatible detonator/initiator.

42 ENGINEERING↗
NASA NTRS1989

Hubble Space Telescope Design Engineering Knowledgebase (HSTDEK)

The research covered here pays specific attention to the development of tools to assist knowledge engineers in acquiring knowledge and to assist other technical, engineering, and management personnel in automatically performing knowledge capture as part of their everyday work without adding any extra work to what they already do. Requirements for data products, the knowledge base, and methods for mapping knowledge in the documents onto the knowledge representations are discussed, as are some of the difficulties of capturing in the knowledge base the structure of the design process itself, along with a model of the system designed. The capture of knowledge describing the interactions of different components is also discussed briefly.

Johannes, James D.↗
DOE OSTI2026

Alchemy: A Model-Based Approach for 2D to 3D Autonomous Nuclear System Design

Engineering design of nuclear power plant (NPP) piping and equipment systems frequently bypasses crucial 2D system planning, instead moving straight to 3D modeling. This often leads to designs that exceed building envelope constraints, forcing expensive and time-consuming redesigns. When 2D modeling is employed, it typically involves labor-intensive manual workflows that convert 2D drawings into 3D models, resulting in inefficiencies and errors across design iterations. These workflows further suffer from poor software interoperability and dependence on proprietary software ecosystems, thereby contributing to schedule delays and cost overruns. This paper presents Alchemy, an autonomous framework that transforms 2D system definitions into Industry Foundation Classes (IFC)-compliant 3D building information models (BIMs) for expediting nuclear facility design at the conceptual preliminary phase. Using a model-based approach, the framework treats the 2D system diagram as the central reference model employed to automatically generate all subsequent outputs, ensuring consistency between the system definition and the resulting physical design. A web-based interface enables engineers to define hierarchical system topologies including associated equipment, geometric properties, and connectivity requirements. A two-phase equipment layout optimization algorithm automatically computes collision-free spatial configurations within predefined building envelopes. An artificial intelligence (AI)-assisted pipe routing module then generates orthogonal, collision-free routing paths, allowing the user to select either an A* search-based method or an Ant Colony Optimization (ACO)-based method. All outputs are authored natively in IFC format, relying on open-source technologies and standardized formats in order to ensure extensibility and eliminate proprietary software dependencies. The proposed framework is validated on two representative pressurized-water reactor (PWR)-based case studies, for which it autonomously generates IFC-compliant 3D models in minutes, drastically reducing workflows that typically require hours of manual effort. The generated model demonstrates topologically correct equipment placement, physically plausible spatial relationships, and collision-free pipe routing consistent with known PWR loop configurations. This work represents a foundational step toward digital engineering for nuclear facility preliminary design, with future ongoing development targeting design code compliance and expanded system complexity.

97 - MATHEMATICS AND COMPUTING↗
NASA NTRSDate not supplied

An Updated Secondary Lunar Meteoroid Ejecta Model for Engineering Design

Introduction: The surface of the Moon is constantly being bombarded by a flux of meteoroids of various sizes. Impacts due to these meteoroids produce secondary ejecta material at much lower speeds but with a total mass larger than the original impactor. Details about the secondary ejecta are important for planning missions on the lunar surface. In this work, an updated ejecta model is presented called the Meteoroid Model of Secondary Ejecta (MeMoSeE), to re-place the Apollo-era ejecta model, NASA SP-8013 [1], in the SLS-SPEC 159 Design Specification for Natural Environments (DSNE) [2]. The model pro-duces secondary ejecta flux environments for a user-specified location on the lunar surface, and sorts the incoming secondary flux by angular direction and speed. Methods: MeMoSeE is separated into three parts: the inputs, the conversion step, and the integration of fluxes. Inputs to the model include the primary meteoroid fluxes and the primary near-Earth object (NEO) fluxes. Meteoroid fluxes, both asteroidal and cometary, are calculated using the Meteoroid Engineering Model (MEM3) [3] for different locations on the Moon. For each surface location, an ephemeris is generated using the JPL HORIZONS System [4] that feeds into MEM3. The NEO fluxes are approximated by the high-density population of MEM3 (i.e., only the directionality), where the speed distribution of the NEO fluxes is renormalized to match observations [5]. The regolith properties are used as defined in the DSNE [2]. The conversion step utilizes scaling laws given by Housen & Holsapple 2011 [6] to convert the primary impactor flux to the total mass of secondary ejecta. The ejecta distribution, at the point-of-impact (POI), is separated into a zenith angle and azimuthal angle distribution. The zenith angle distribution follows a beta distribution where the peak depends on the impact altitude angle and the impact azimuth [7]. We employ an ejecta azimuth distribution that is based on Rival & Mandeville 1999 [8] which focuses ejecta in the downstream direction for more oblique impacts. Finally, during the integration step, we sum secondary ejecta number fluxes at a particular region-of-interest (ROI) that originated from many POI locations over the entire surface of the Moon. We keep track of both altitude and azimuth angle bins as well as a range of speed bins, following the igloo gridding as done in MEM3 [9]. The ejecta particle size distribution and density is assumed to be the same as the lunar regolith [10, 2]. Results: The primary fluxes are computed for one Metonic cycle (19 years) for various locations over the lunar surface with a fixed orientation. Both the angular and speed distributions of the primary fluxes are dependent on the latitude and longitude. The over-all primary fluxes show a roughly 13% increase from the eastern limb to the western limb. In general, the speed distribution of the secondary fluxes span from a user-defined minimum speed to the escape speed of the Moon (2.38 km/s), roughly following a power-law relation [6]. Different parts of the speed distribution come from different primary impact locations on the Moon. The secondary ejecta is dominated by the slowest speeds, where these particles originate nearby the ROI. For speeds around 71% of the escape speed, the secondary ejecta originates from locations near the antipodal point. On the other hand, for secondary ejecta speeds that exceed roughly 90% the escape speed, the ejecta particles come from all over the lunar surface to the ROI. Comparing the secondary ejecta fluxes from MeMoSeE with NASA SP-8013 [1], there is a reduction by about 2-3 orders of magnitude for secondary ejecta particles greater than 1 µg. These estimates agree with recent findings from Bjorkman & Christiansen 2019 [11]. The secondary ejecta fluxes are also compared with the primary fluxes, where the ejecta fluxes are roughly an order of magnitude greater than the primary fluxes. References: [1] Cour-Palais, B. G., (1969) NASA SP-8013. [2] NASA SLS-SPEC-159 Rev. H (2020). [3] Moorhead, A. V., et al. (2019) JS&R, 1-17. [4] Giorgini, J. D., (2015) IAUGA, 29, 2256293. [5] Moorhead, A. V., (2020) Memo OSMA/MEO/Lunar-001. [6] Housen, K. R., and Holsapple, K. A., (2011) Icarus, 211(1), 856-875. [7] Gault, D. E., and Wedekind, J. A., (1978) L&PSCP, 9, 3843-3875. [8] Rival, M., and Mandeville, J., (1999) Space Debris, 1(1), 45-57. [9] Moorhead, A. V., (2019) MEM3 User Guide. [10] Carrier, W. D., (1973) The Moon, 6(3-4), 250-263. [11] Bjorkman, M. D. & Christiansen, E. L., (2019) ODC

impacts↗
NASA NTRS1996

Transportation Beyond 2000: Technologies Needed for Engineering Design

The purpose of the workshop was to acquaint the staff of the NASA Langley Research Center with the broad spectrum of transportation challenges and concepts foreseen within the next 20 years. The hope is that the material presented at the workshop and contained in this document will stimulate innovative high-payoff research directed towards the efficiency of future transportation systems. The workshop included five sessions designed to stress the factors that will lead to a revolution in the way we will travel in the 21st century. The first session provides the historical background and a general perspective for future transportation, including emerging transportation alternatives such as working at a distance. Personal travel is the subject of Session Two. The third session looks at mass transportation, including advanced rail vehicles, advanced commuter aircraft, and advanced transport aircraft. The fourth session addresses some of the technologies required for the above revolutionary transportation systems to evolve. The workshop concluded with a wrap-up panel discussion, Session Five. The topics presented herein all have viable technical components and are at a stage in their development that, with sufficient engineering research, one or more of these could make a significant impact on transportation and our social structure.

Huebner, Lawrence D.↗
NASA NTRS1996

Transportation Beyond 2000: Technologies Needed for Engineering Design

The purpose of the workshop was to acquaint the staff of the NASA Langley Research Center with the broad spectrum of transportation challenges and concepts foreseen within the next 20 years. The hope is that material presented at the workshop and contained in this document will stimulate innovative high-payoff research directed towards the efficiency of future transportation systems. The workshop included five sessions designed to stress the factors that will lead to a revolution in the way we will travel in the 21st century. The first session provides the historical background and a general perspective for future transportation, including emerging transportation alternatives such as working at a distance. Personal travel is the subject of Session Two. The third session looks at mass transportation, including advanced rail vehicles, advanced commuter aircraft, and advanced transport aircraft. The fourth session addresses some of the technologies required for the above revolutionary transportation systems to evolve. The workshop concluded with a wrap-up panel discussion, Session Five. The topics presented herein all have viable technical components and are at a stage in their development that, with sufficient engineering research, one or more of these could make a significant impact on transportation and our social structure.

Huebner, Lawrence D.↗
NASA NTRS2011

Z-Pinch Magneto-Inertial Fusion Propulsion Engine Design Concept

Fusion-based nuclear propulsion has the potential to enable fast interplanetary transportation. Due to the great distances between the planets of our solar system and the harmful radiation environment of interplanetary space, high specific impulse (Isp) propulsion in vehicles with high payload mass fractions must be developed to provide practical and safe vehicles for human spaceflight missions. Magneto-Inertial Fusion (MIF) is an approach which has been shown to potentially lead to a low cost, small fusion reactor/engine assembly (1). The Z-Pinch dense plasma focus method is an MIF concept in which a column of gas is compressed to thermonuclear conditions by an estimated axial current of approximately 100 MA. Recent advancements in experiments and the theoretical understanding of this concept suggest favorable scaling of fusion power output yield as I(sup 4) (2). The magnetic field resulting from the large current compresses the plasma to fusion conditions, and this is repeated over short timescales (10(exp -6) sec). This plasma formation is widely used in the field of Nuclear Weapons Effects (NWE) testing in the defense industry, as well as in fusion energy research. There is a wealth of literature characterizing Z-Pinch physics and existing models (3-5). In order to be useful in engineering analysis, a simplified Z-Pinch fusion thermodynamic model was developed to determine the quantity of plasma, plasma temperature, rate of expansion, energy production, etc. to calculate the parameters that characterize a propulsion system. The amount of nuclear fuel per pulse, mixture ratio of the D-T and nozzle liner propellant, and assumptions about the efficiency of the engine, enabled the sizing of the propulsion system and resulted in an estimate of the thrust and Isp of a Z-Pinch fusion propulsion system for the concept vehicle. MIF requires a magnetic nozzle to contain and direct the nuclear pulses, as well as a robust structure and radiation shielding. The structure, configuration, and materials of the nozzle must meet many severe requirements. The configuration would focus, in a conical manner, the Deuterium-Tritium (D-T) fuel and Lithium-6/7 liner fluid to meet at a specific point that acts as a cathode so the Li-6 can serve as a current return path to complete the circuit. In addition to serving as a current return path, the Li liner also serves as a radiation shield. The advantage to this configuration is the reaction between neutrons and Li-6 results in the production of additional Tritium, thus adding further fuel to the fusion reaction and boosting the energy output. To understand the applicability of Z-Pinch propulsion to interplanetary travel, it is necessary to design a concept vehicle that uses it. The propulsion system significantly impacts the design of the electrical, thermal control, avionics, radiation shielding, and structural subsystems of a vehicle. The design reference mission is the transport of crew and cargo to Mars and back, with the intention that the vehicle be reused for other missions. Several aspects of this vehicle are based on a previous crewed fusion vehicle study called Human Outer Planet Exploration (HOPE), which employed a Magnetized Target Fusion (MTF) propulsion concept. Analysis of this propulsion system concludes that a 40-fold increase of Isp over chemical propulsion is predicted. This along with a greater than 30% predicted payload mass fraction certainly warrants further development of enabling technologies. The vehicle is designed for multiple interplanetary missions and conceivably may be suited for an automated one-way interstellar voyage.

Miernik, Janie H.↗
DOE OSTI2025

Engineering design of a kW-scale continuous reactor-heat exchanger for high temperature discharge of particle-based thermochemical energy storage

This study investigates the theoretical design parameters and thermal performance of a kW-scale continuous oxidation reactor for high temperature (~1000 °C) thermochemical energy storage (TCES) applications. The concept comprises a counter-current particle-based system that includes a reaction zone with a heat exchanger to extract the heat produced from the oxidation reaction. Both above and below the hot reactive volume are sensible heat recuperation zones to enable the feed and removal of particles and oxidizing gas near ambient temperature during steady state operation. Two operation types for the reaction zone are studied, a fluidized bed reactor (FBR) and a moving bed reactor (MBR). The results of the parametric analysis suggest that the MBR requires a smaller volume per kW of heat produced, achieving power densities in excess of 2500 kW/m3 compared to ~ 900 kW/m 3 in the FBR. Additionally, the MBR achieves between 0.71 and 0.99 oxidation conversions compared to between 0.23 and 0.38 conversions in the FBR with the same volumes and flowrates. However, the FBR has the potential to maintain a uniform reactor temperature which can produce heat transfer fluid (HTF) outlet temperatures as high as the reactor temperature, i.e., ~1000 °C, whereas the MBR produces variable reactor temperatures that can create overheating zones and low HTF outlet temperatures (< 800 °C) depending on the operating conditions selected. Future work should aim at understanding the coupled fluid dynamics, heat and mass transfer, and thermochemical reaction for any given combination of reactor volume and contacting patterns. Here, these studies should be complemented by experimental work on particle-gas TCES reactors.

25 ENERGY STORAGE↗
DOE OSTI2024

Nuclear Thermal Energy Storage Configurations for Industrial Combined Heat and Power Supply: Conceptual Study and Engineering Designs

The industries examined in this report primarily rely on moderate-temperature heat provided by gas- or coal-fired boilers and combined heat and power (CHP) plants, delivered through standard process steam systems. High-temperature energy demands are often industry-specific and typically exceed the capabilities of high-temperature gas-cooled reactors (HTGRs). While it is technically feasible to replace process steam from fossil-based heat sources with nuclear energy, certain industries, such as methanol production and pulp and paper, face technoeconomic challenges in integrating nuclear energy without major changes or a technological shift. This is mainly due to the limited external energy demand remaining after the use of internal byproducts, waste heat recovery, and simple efficiency improvements. Achieving full decarbonization of these processes with nuclear energy would require significant technological advancements, involving experimental technology and substantial investments, making widespread adoption in existing industrial plants unlikely in the near term. This study reviews TES options in the context of enabling a flexible CHP supply while maintaining a steady nuclear heat input. Heat storage systems that interface between the reactor primary fluid and the CHP system offer superior performance and flexibility. Specifically, steam extraction downstream of the reheater with a two-tank molten-salt TES appears as the best solution regarding thermodynamic system benefits and system drawbacks. Using selected system configurations, a conceptual design of an industrial energy park was developed for industries with varying energy demands, such as steel production plants utilizing electric arc furnaces (EAFs) and chemical plants, as well as for those with constant energy demands, like petroleum refineries. This design highlights the capabilities of TES and explores its potential business cases. The study also conceptually develops the potential for integrating additional energy sources with nuclear systems through the implementation of TES. The potential of the HTGR-TES-CHP system was also evaluated considering key uncertainties such as industrial demand profiles, external grid access availability, and eligible tax credit levels, using the Holistic Energy Resource Optimization Network. Sensitivity of net present value to these uncertainties was analyzed to determine the optimal number of nuclear reactors (and CHP systems) and the suitable TES capacity. The results were interpreted from a decision-maker’s perspective, focusing on three key areas: deployment strategy (oversized units vs. undersized units with TES support), industrial process characteristics (thermal-intensive single profiles vs. electricity-intensive combined profiles), and operational goals (maximizing profits vs. minimizing natural gas (NG) consumption or external grid dependence). The optimization results indicate that the HTGR-TES-CHP system significantly reduces reliance on NG boilers for individual industrial processes by 9-60% (in NG capacity factor), with an average reduction of 38%, compared to standalone NG boiler operation case (Business As Usual [BAU]). For combined industrial processes, the reduction ranges from 37-77%, with an average of 60%. Additionally, the system greatly reduces dependence on external grids. In meeting industrial electrical demands, a 33-100% self-sufficient internal electricity supply is achieved for single industrial process, with an average of 74%, compared to the BAU scenario, where 100% of electricity is imported. For combined processes, 35-100% of internal electricity demands are met by the reactor, with an average of 73%. At last, the relative NG price levels at which the proposed HTGR-TES-CHP system can cost-effectively enter the market currently dominated by existing NG boilers were estimated. For a moderate HTGR CAPEX level ($\$$2500/kWth, $\$$6329/kWe), the analysis suggests that NG prices must be 2.5 to 7 times higher than HTGR variable operating and maintenance costs for single industrial process, and 5.5 to 9.5 times higher for a combined process scenario. Tax credit modeling shows that the Investment Tax Credit significantly reduces the price threshold needed to break even, making the system competitive with NG boilers in certain cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Front-end engineering design (FEED) studies: a quantitative analysis

NETL has devised a methodology for normalizing FEED study metrics of interest and allowing cautious quantitative comparison across FEED studies. This presentation introduces the novel quantitative comparison methodology and presents results from utilizing this methodology to examine data presented in recent FEED study reports. The quantitative methodology developed for the examination of FEED study performance and cost also allows comparison of real-world performance and costs against NETL TEA model predicted performance and cost. Learnings from examining NETL model predicted performance and cost versus real world reported values are highlighted. These learnings provide insight into NETL TEA model uncertainty and highlight opportunities for further model development.

FEED Studies↗