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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Design Considerations for Phase Change Material-Incorporated Heat Exchangers in Water Heating

In recent years, the buildings sector has seen major pushes towards decarbonization through innovations that promote deep electrification. 20% of an average household's energy use comes from water heating, and in the US, over half of all households still use gas water heaters. Of those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. However, HPWHs tend to have larger dimensions, preventing current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). This study outlines the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. To ensure optimal PCM utilization and tank storage capacity, this works seeks to co-maximize surface area and PCM volume; therefore, this research targets triply periodic minimal surface (TPMS) lattices, which boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives. Our current results indicate that tuning lattice properties can effectively produce geometries that provide enough energy storage to achieve a 50-gallon capacity out of a 40-gallon HPWH, even when placing the PCM heat exchanger inside the tank. Additionally, we demonstrate successful fabrication of lattices with these tuned properties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1994

Oscillating-flow regenerator test rig

This report summarizes work performed in setting up and performing tests on a regenerator test rig. An earlier status report presented test results, together with heat transfer correlations, for four regenerator samples (two woven screen samples and two felt metal samples). Lessons learned from this testing led to improvements to the experimental setup, mainly instrumentation as well as to the test procedure. Given funding and time constraints for this project it was decided to complete as much testing as possible while the rig was set up and operational, and to forego final data reduction and analysis until later. Additional testing was performed on several of the previously tested samples as well an on five newly fabricated samples. The following report is a summary of the work performed at OU, with many of the final test results included in raw data form.

Wood, J. G.↗
NASA NTRS1994

Optimization of Adaptive Intraply Hybrid Fiber Composites with Reliability Considerations

The reliability with bounded distribution parameters (mean, standard deviation) was maximized and the reliability-based cost was minimized for adaptive intra-ply hybrid fiber composites by using a probabilistic method. The probabilistic method accounts for all naturally occurring uncertainties including those in constituent material properties, fabrication variables, structure geometry, and control-related parameters. Probabilistic sensitivity factors were computed and used in the optimization procedures. For actuated change in the angle of attack of an airfoil-like composite shell structure with an adaptive torque plate, the reliability was maximized to 0.9999 probability, with constraints on the mean and standard deviation of the actuation material volume ratio (percentage of actuation composite material in a ply) and the actuation strain coefficient. The reliability-based cost was minimized for an airfoil-like composite shell structure with an adaptive skin and a mean actuation material volume ratio as the design parameter. At a O.9-mean actuation material volume ratio, the minimum cost was obtained.

Shiao, Michael C.↗
NASA NTRS1995

Laser Doppler Velocimetry and full-field soot volume fraction

Since its introduction in the mid-sixties, Laser Doppler Velocimetry (LDV) has become one of the most widely used methods for the measurement of flows. Its remote and essentially non-intrusive nature provides an invaluable tool for a variety of difficult measurement situations which would be otherwise inaccessible. The high spatial resolution and rapid temporal response afforded by this technique are well suited to the determination of spatial and temporal details of flow fields, as well as characterization of turbulence. Advances in the understanding of the properties of LDV signals, accompanied by technological advances in coherent laser sources, detectors of high sensitivity and low noise, optical fabrication techniques and high-speed digital signal processing architectures have resulted in systems of increased accuracy and flexibility. As will be shown, recent progress in solid-state lasers and photo-detectors has been beneficial insofar as the compatibility of this method with the unique and severe constraints inherent in microgravity combustion science experiments.

Greenberg, Paul S.↗
NASA NTRS2012

Variable Sampling Mapping

The performance of an optical system (for example, a telescope) is limited by the misalignments and manufacturing imperfections of the optical elements in the system. The impact of these misalignments and imperfections can be quantified by the phase variations imparted on light traveling through the system. Phase retrieval is a methodology for determining these variations. Phase retrieval uses images taken with the optical system and using a light source of known shape and characteristics. Unlike interferometric methods, which require an optical reference for comparison, and unlike Shack-Hartmann wavefront sensors that require special optical hardware at the optical system's exit pupil, phase retrieval is an in situ, image-based method for determining the phase variations of light at the system s exit pupil. Phase retrieval can be used both as an optical metrology tool (during fabrication of optical surfaces and assembly of optical systems) and as a sensor used in active, closed-loop control of an optical system, to optimize performance. One class of phase-retrieval algorithms is the iterative transform algorithm (ITA). ITAs estimate the phase variations by iteratively enforcing known constraints in the exit pupil and at the detector, determined from modeled or measured data. The Variable Sampling Mapping (VSM) technique is a new method for enforcing these constraints in ITAs. VSM is an open framework for addressing a wide range of issues that have previously been considered detrimental to high-accuracy phase retrieval, including undersampled images, broadband illumination, images taken at or near best focus, chromatic aberrations, jitter or vibration of the optical system or detector, and dead or noisy detector pixels. The VSM is a model-to-data mapping procedure. In VSM, fully sampled electric fields at multiple wavelengths are modeled inside the phase-retrieval algorithm, and then these fields are mapped to intensities on the light detector, using the properties of the detector and optical system, for comparison with measured data. Ultimately, this model-to-data mapping procedure enables a more robust and accurate way of incorporating the exit-pupil and image detector constraints, which are fundamental to the general class of ITA phase retrieval algorithms.

Smith, Jeffrey, S.↗
DOE OSTI2022

Stellarator coil design using cubic splines for improved access on the outboard side

In recent years many efforts have been undertaken to simplify coil designs for stellarators due to the difficulties in fabricating non-planar coils. Additionally, the FOCUS code removes the need for a winding surface and represents the coils as arbitrary curves in 3D. In the following work, the implementation of a spline representation for the coils in FOCUS is described, along with the implementation of a new engineering constraint to design coils with a straighter outer section. The new capabilities of the code are shown as an example on HSX, NCSX, and a prototype quasi-axisymmetric reactor-sized stellarator. The flexibility granted by splines along with the new constraint will allow for stellarator coil designs with improved accessibility and simplified maintenance.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1985

Thin-film module circuit design: Practical and reliability aspects

This paper will address several aspects of the design and construction of submodules based on thin film amorphous silicon (a-Si) p i n solar cells. Starting from presently attainable single cell characteristics, and a realistic set of specifications, practical module designs are discussed from the viewpoints of efficient designs, the fabrication requirements, and reliability concerns. The examples center mostly on series interconnected modules of the superstrate type with detailed discussions of each portion of the structure in relation to its influence on module efficiency. Emphasis is placed on engineering topics such as: area coverage, optimal geometries, and cost and reliability. Practical constraints on achieving optimal designs, along with some examples of potential pitfalls in the manufacture and subsequent performance of a-Si modules are discussed.

Daiello, R. V.↗
NASA NTRS1996

Optimization of residual stresses in MMC's through the variation of interfacial layer architectures and processing parameters

The objective of this work was the development of efficient, user-friendly computer codes for optimizing fabrication-induced residual stresses in metal matrix composites through the use of homogeneous and heterogeneous interfacial layer architectures and processing parameter variation. To satisfy this objective, three major computer codes have been developed and delivered to the NASA-Lewis Research Center, namely MCCM, OPTCOMP, and OPTCOMP2. MCCM is a general research-oriented code for investigating the effects of microstructural details, such as layered morphology of SCS-6 SiC fibers and multiple homogeneous interfacial layers, on the inelastic response of unidirectional metal matrix composites under axisymmetric thermomechanical loading. OPTCOMP and OPTCOMP2 combine the major analysis module resident in MCCM with a commercially-available optimization algorithm and are driven by user-friendly interfaces which facilitate input data construction and program execution. OPTCOMP enables the user to identify those dimensions, geometric arrangements and thermoelastoplastic properties of homogeneous interfacial layers that minimize thermal residual stresses for the specified set of constraints. OPTCOMP2 provides additional flexibility in the residual stress optimization through variation of the processing parameters (time, temperature, external pressure and axial load) as well as the microstructure of the interfacial region which is treated as a heterogeneous two-phase composite. Overviews of the capabilities of these codes are provided together with a summary of results that addresses the effects of various microstructural details of the fiber, interfacial layers and matrix region on the optimization of fabrication-induced residual stresses in metal matrix composites.

Pindera, Marek-Jerzy↗
DOE OSTI2026

Thermokinetic mixing compounding for polymer composites – a comprehensive review

High-speed thermokinetic mixers (K-mixers) represent an advanced compounding technology that employs intense shear and friction to convert kinetic energy directly into thermal energy. This mechanism enables rapid mixing cycles, often under one minute, facilitating exceptional filler dispersion while minimizing the material’s thermal history. This is particularly effective for compounding challenging materials, including heat-sensitive biopolymers, wet filler feedstocks, and nanofillers prone to agglomeration. As the first comprehensive review of this technology, this article synthesizes the fundamental principles of thermokinetic mixing (K-mixing) and surveys recent advances in polymer composite fabrication. We contrast the working principles of K-mixers with conventional twin-screw extrusion, highlighting distinct advantages in dispersing nanoscale fillers, exfoliating layered materials, and processing wet cellulosic feedstocks and ultra-high filler loadings (e.g., 85 wt%). Furthermore, strategies to optimize filler–matrix interfacial bonding under rapid-processing constraints, such as the kinetic selection of compatibilizers and fiber surface treatments, are evaluated. Finally, we analyze key structure-processing-property relationships and outline future directions in scaling up, reactive processing, and hybrid material development.

Zhang, Xuefeng [University of Maine]↗
DOE OSTI2021

Design and Analysis of an Advanced Three-Point Bend Test Approach for Miniature Irradiated Disk Specimens

Candidate tungsten armor materials in a magnetic confinement fusion device must be able to withstand thermal variation that leads to internal stresses caused by the impinging heat load. In addition, the thermomechanical properties of these materials are degraded by irradiation-induced defect accumulation. Fission reactor–based irradiation data are used to predict the fusion neutron damage and property change. This study examines the motivation and design of a custom-designed three-point bend test for neutron-irradiated disk specimens that are 3 mm in diameter to be able to define the flexural strength of advanced tungsten materials, alloys, and composites—and to the extent that embrittlement occurs after neutron irradiation. The theory provided shows a calculation for the flexural deflection and shear deflection due to the small-geometry constraints. A finite element deformation analysis is performed to evaluate the mechanical stress field of disk bend specimens. The stress values above 80% of the maximum stress are concentrated in 2.4 mm of the 3.0-mm length of the centerline across the tungsten disk diameter. A bend test fixture has been designed and fabricated to enable testing of these specimens with precisely engineered tolerance and minimal machine compliance. This fixture will be able to be placed inside a universal testing frame at elevated temperatures for the mechanical property evaluation of future neutron-irradiated disk specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sub-Scale Stage 1 Magnetic Gear for a Marine Hydrokinetic Generator

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. Measurement data for a 9.5:1 gear ratio magnetic gear with a measured peak torque of 227 N-m as well as the dual stage magnetic gear with a 63:1 gear ratio.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Stage 2 Sub-Scale Magnetic Gear

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. 7.67:1 gear ratio magnetic gear with a measured peak torque of 1796 N-m

16 TIDAL AND WAVE POWER↗
NASA NTRS1989

Design and testing of thermal-expansion-molded graphite-epoxy hat-stiffened sandwich panels

Minimum weight configurations for two types of graphite-epoxy hat-stiffened compression-loaded panels fabricated by the thermal-expansion-molding (TEM) manufacturing process were evaluated analytically and experimentally for designs with load index Nx/L values ranging from 100 to 800. The two types of panels contain graphite-epoxy face sheets with a foam core and hat stiffeners which are either open or filled with foam. Constraints on the extensional and shear stiffnesses are imposed on the design so that the panels will satisfy typical constraints for aircraft wing structures. Optimal structurally efficient TEM panels are compared to commercially available aluminum aircraft structures. Predicted load-strain relationships agree well with experimental results. Significant impact damage to the unstiffened face sheet and foam core does not noticeably reduce the load carrying ability of the panels, but damage to the stiffened face sheet reduces the failure load by 20 percent compared to unimpacted panels.

Jegley, Dawn C.↗
DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Scaling open-weight large language models for hydropower regulatory information extraction: A systematic analysis

Information extraction from regulatory and technical documents using large language models (LLMs) involves practical trade-offs between extraction quality and computational cost. We evaluate eight open-weight LLMs spanning 0.6B–70B parameters on hydropower licensing documents and report deployment-oriented evidence under a unified extraction schema and evaluation protocol. Across the model set, we observe clear scale-dependent trends in both baseline extraction quality and the effectiveness of reflective reasoning (self-checking) under our fixed-prompt, no-augmentation setting. Mid-scale models often provide a favorable balance of accuracy and efficiency, whereas the smallest models show limited or inconsistent gains from the reasoning variants tested. Larger models achieve the highest overall F1 scores but incur substantially greater compute and infrastructure requirements. We further find that reliability failure modes can distort conventional metrics in this domain: in particular, high recall can coincide with systematic extraction errors when models fabricate values for fields that are absent from the source text, underscoring the importance of conservative null handling and evidence-grounded evaluation. Overall, our study provides a reproducible resource–performance comparison for open-weight LLM-based extraction in hydropower regulatory documentation and offers practical guidance for model selection under different deployment constraints.

Evaluation protocol↗
DOE OSTI2020

Radiation-hard miniature optical engine with high bandwidth

Future silicon trackers will be operated in an intense radiation environment and require large volumes of data to be transmitted off detector. In addition, the optical modules must be of low mass in order to limit multiple scattering and nuclear interactions that would degrade the overall performance of the detector. Here, we present a miniature optical engine that satisfies these constraints. The optical engine consists of an ASIC driving a VCSEL (Vertical Cavity Surface Emitting Laser) array in an optical package. Two ASICs are designed to operate a 12-channel VCSEL array at 1.28 or 5.12 Gb/s per channel, which yields a total data rate of up to 60 Gb/s. The core transistors are fabricated in a 65 nm CMOS process which enhance the radiation-hardness. Each channel contains equalizer (CTLE) and clock-data recovery circuits (CDR) so that the ASIC can restore the highly distorted electrical signal after propagating through several meters of cables of small diameter. The equalizer, CDR, and VCSEL driver are configured via a digital I 2 C chip interface with triple redundant memory to mitigate single event upset (SEU) effects. The bias and modulation currents are controlled by a digital-to-analog converter (DAC). We present the design of the circuit together with the results of the simulations and preliminary measurements.

47 OTHER INSTRUMENTATION↗
NASA NTRS1975

Conceptual design study of 1985 commercial VTOL transports that utilize rotors

Conceptual design studies of pure and compound helicopter commercial short-haul transport aircraft for initial fabrication in 1980 were performed to determine their technical and economic feasibility. One-hundred-passenger configurations were optimized for minimum direct operating cost consistent with producibility and marketability, with emphasis on proper account of mass properties, performance and handling qualities adequacy, and suppression of internal and external noise. The effect of external noise constraints was assessed, in terms of gross weight and direct operating cost, for each aircraft.

Kefford, N. F. K.↗
NASA NTRS2014

Aeroelastic Optimization Study Based on X-56A Model

A design process which incorporates the object-oriented multidisciplinary design, analysis, and optimization (MDAO) tool and the aeroelastic effects of high fidelity finite element models to characterize the design space was successfully developed and established. Two multidisciplinary design optimization studies using an object-oriented MDAO tool developed at NASA Armstrong Flight Research Center were presented. The first study demonstrates the use of aeroelastic tailoring concepts to minimize the structural weight while meeting the design requirements including strength, buckling, and flutter. A hybrid and discretization optimization approach was implemented to improve accuracy and computational efficiency of a global optimization algorithm. The second study presents a flutter mass balancing optimization study. The results provide guidance to modify the fabricated flexible wing design and move the design flutter speeds back into the flight envelope so that the original objective of X-56A flight test can be accomplished.

flutter constraints↗