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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 OSTI2024

Review and Gap Analysis of Heliostat Components and Controls

This investigation provides a comprehensive literature review pertaining to heliostat components and controls as part of the U.S. Department of Energy (DOE), Heliostat Consortium (Heliocon) program. Here, this work presents a detailed assessment of subcomponents, controls and wireless communications elements that comprise various designs of helisotats within concentrating solar power (CSP) installations. Additionally, this work also provides the results of an industry survey, intended to compliment the literature discussion, to provide a gap analysis of the primary technology and cost areas that need to be addressed to help improved to spur concentrating solar power (CSP) bankability. Although the results of the study determined several key areas for development, three strategic areas identified were: (1) the use of advanced composite materials to replace a need for expensive steel within the structure and mirror substrate, (2) employment of closed-loop controls for automated calibration, reduction of commissioning time and O&M hours, reduction of drive requirements, as well as overall cost reduction, and (3) the need for more Heliostat-centric codes and standards to facilitate engineering confidence in the development of new features, cost reductions, or other design iterations to be seamlessly introduced without optical performance problems.

14 SOLAR ENERGY↗
DOE OSTI2026

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.

Singh, Abhishek [University of Michigan, Ann Arbor↗
DOE OSTI2024

Design by analysis rules for ASME Section III, Division 5, Class B components

The current rules for elevated temperature ASME Section III, Division 5, Class B components, other than piping, were basically adapted from the Design-by-Rule approach for Section VIII, Division 1 vessels. A goal of the proposed new rules is to explicitly account for the design life and cyclic service while recognizing the less-rigorous requirements commensurate with lesser safety consideration. Further goals are to maximize the use of modern computational technology, for example finite element analysis in conjunction with reference stress concepts, and to avoid the need for stress classification. This paper summarizes the work done to address these issues. A summary of the design-by-analysis for primary loads, strain limit evaluation, and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules and the experimental data obtained from a family of a simplified model test-based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Digital-Twin-Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable optimized scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins (DTs) are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. DTs for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. A DT’s goal is to provide additional insights by combining and interpreting various sources of information for preventative maintenance scheduling optimization or early fault detection. DTs for condition monitoring are projected to be valuable for meeting requirements under 10 CFR 50.55a, “Codes and Standards,” and 10 CFR 50.65, “Requirements for Monitoring the Effectiveness of Maintenance at Nuclear Power Plants”. However, DT technologies are still under significant development, and the process for developing a DT for condition monitoring has not been formalized. Therefore, in this work, we present an initial framework for developing a DT, discuss and review the various challenges and considerations for DT deployment, and identify the opportunities that a DT can improve. The presented framework is intended to help developers formulate a strategy when approaching DT development for condition monitoring. In conclusion, a DT use case for a reactor coolant pump is presented to demonstrate the proposed framework.

advanced sensor instrumentation↗
DOE OSTI2025

FIRM image analysis: A machine learning workflow for quantifying extracellular matrix components from electron microscopy images

The extracellular matrix (ECM) is a complex network of biomolecules that plays an integral role in the structure, processes, and signaling mechanisms of cells and tissues. Identifying and quantifying changes in these matrix components provides insight into the mechanisms behind specific tissue remodeling processes; however, quantifying these changes is challenging due to difficult imaging conditions, complexity of the ECM, and the subtlety of these changes. Current imaging techniques allow us to visualize these critical remodeling events and developments in image analysis have employed a combination of analysis software and machine learning techniques to improve the efficiency and accuracy with which features are measured. Although image analysis has seen much improvement in recent years, there has been no technique developed to address ambiguity in feature edges in electron microscopy images. Presented here is a new machine learning-based workflow for the analysis of microscopy images named FIRM (Feature Identification from Raw Microscopy) that uses a random forest classifier to identify ECM features of interest and generate binary segmentation masks for quantification with ImageJ-FIJI. FIRM performed with an F1 score of 0.794 and greater than 80% accuracy for number and size of features detected. FIRM had similar deviation from the ground truth in the number of identified fibrils, fibril size, and size distributions when compared to human analyses. The results suggest that FIRM performs as well as manual analysis and requires a fraction of the time. This analysis technique is more efficient, eliminates user bias, and can be easily optimized to identify a variety of features, making it useful for any discipline requiring image analysis.

Science & Technology - Other Topics↗
DOE OSTI2024

Component-to-Optimization Workflow Demonstration

This report aims to demonstrate workflow-generating algorithms for optimizing dispatch across a broad range of Integrated Energy System applications using the Framework for Optimization of Resources and Economics (FORCE) tool suite. The optimization is performed at two different time scales. In the coarse time scale, the optimization focuses on a class of energy sources and consumers and aims to find the optimal combinations and flows of energy based on real-time price data information. In the fine time scale, the optimization focuses on a specific thermal energy delivery system and aims to find the optimal setpoints of components in order to meet the energy demands from coarse-time-scale optimizations. In this demonstration, the coarse-scale optimization is implemented using the newly developed Dispatch Optimization Variable Engine (DOVE), while the fine-scale optimization used Optimization of Real-Time Capacity Allocation (ORCA).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Assessment of Heavy-Duty Fueling Methods and Components

Building on the successful commissioning and demonstration of NREL's heavy-duty (HD) fast flow research facility under the Innovating Hydrogen Station's Project, researchers advanced R&D activities to the next phase under a new project titled, Assessment of Heavy-Duty Fueling Methods and Components. This Cooperative Research and Development Agreement (CRADA) is led by NREL in partnership with NextEnergy, Argonne National Laboratory, and Chevron with NextEnergy representing a larger group of industry partners that includes AirLiquide, Hyundai, Nel, Nikola, Shell, and Toyota. The CRADA seeks to develop a comprehensive assessment of HD fuel cell electric vehicle fueling protocols and fueling hardware to understand the effects of fueling protocol architectures on station design, vehicle design, functional safety requirements, and the implications on the total cost of ownership (TCO) and techno economic assessment (TEA).

class 8 truck↗
DOE OSTI2024

Metal-to-Ceramic Joining Methods to Support Development of Advanced Ceramic-Based CSP Components

The National Renewable Energy Laboratory, Missouri University of Science and Technology (MS&T), Massachusetts Institute of Technology (MIT), and Colorado School of Mines (CSM) collaborated to design, develop, and test a material concept at bench scale which will be used to achieve a ceramic-to-metal (C2M) joint between a selected metal HTF loop material and a selected ceramic material used by the Gen3 CSP technology pathway. The final joint assembly will need to possess sufficient mechanical properties to withstand static high-temperature (650 degrees-700 degrees C) and high-pressure (20 MPa) and thermal cycling (between 650 degrees C and 100 degrees C) conditions. The material concept consists of three key components: (1) a ceramic matrix composite (CMC) that serves as a compliant transition material aiming to mitigate the stresses due to the mismatch of coefficient of thermal expansion (CTE) from a direct ceramic-to-metal joint, (2) a metal-end joint utilizing a multi-principal element alloy (MPEA) with changing percentage of particle loading to bond the candidate metal to the CMC, and (3) a ceramic-end joint utilizing a glass ceramic to bond the candidate ceramic to the CMC.

14 SOLAR ENERGY↗
DOE OSTI2024

Quantification of the Crack Evolution Process by Extracting Relevant Signal Components from Wave Propagation and Diffusive Transport Front Measurements

Wave propagation and diffusive transport phenomena in a geological rock sample undergoing crack evolution process are expected to interact with the mechanical discontinuities in the medium. The measurements of the signals associated with these phenomena can be used to assess and monitor the crack-driven micromechanical alterations in the rock. Different wave/diffusion phenomena, such as sonic propagation, pressure diffusion, and acoustic emission (AE), are sensitive to different elements of the mechanical discontinuities generated during the evolution of the crack clusters from initiation to coalescence. Sonic propagation, AE, and pressure diffusion monitoring have the potential to map the crack evolution because the transmitter-receiver arrays can be designed, arranged and tuned to (1) achieve maximum recovery of the scattered waveforms and travel times, (2) capture the later arrivals and multiple reflections, and (3) illuminate large rock volume. However, the structural/topological complexities of the mechanical discontinuities, complex distribution of the stress fields, complex mechanical alterations in media, and fluid redistribution in the crack system pose serious challenges for the detection and modeling of the crack evolution process (from here on, we will use the term ‘crack evolution process’ to mean that the crack evolution occurred under shallow crustal conditions). For purposes of accurately accounting such complexities and heterogeneities in the absence of reliable physical laws, simulation methods, and signal processing techniques, my early-career research proposal will develop and apply novel data-driven machine learning methods to: (1) extract signal components relevant to the various phases of crack evolution and (2) generate a 2D visual map of the crack evolution process.

58 GEOSCIENCES↗
DOE OSTI2024

Sensitivity Analysis for the Component Design App: Analysis of Success Assured Data

A new tool has been developed to perform variance-based global sensitivity analysis (VBGSA) on data from a set-based concurrent engineering software called Success Assured (SA). The tool is part of a digital component design app, which is currently in production as an Accelerated Digital Engineering Pathfinder at Sandia National Laboratories. When working with complex digital models, it is important to understand relationships between inputs and outputs, i.e., how “sensitive” model outputs are to changes in model inputs. After extensive research and trials of various sensitivity analysis methods, it was determined that estimation of Sobol’ indices for VBGSA with Monte Carlo simulation, paired with simple surrogate models, produces the best results for SA data. This tool increases understanding of SA models and streamlines the creation of SA datasets. This report details the methodology and implementation of this sensitivity analysis tool so others can understand it and implement it.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Solid State Additive Manufacturing of Oxide Dispersion Strengthened-FeCrAl Alloy Components for High-Temperature Supercritical CO2 Power Cycle Applications

In this research, material extrusion additive manufacturing (MEAM) has been explored as an SSAM method for fabrication of 3-D components using ODS-FeCrAl alloy. MEAM-printed 3-D parts go through a series of process steps, e.g., chemical treatment, thermal treatment etc. in order to create a high density fully metallic part. Final 3-D part quality is associated with various process steps, e.g., filament fabrication, print design, and thermal treatment optimization. In MEAM, a metal powder loaded filament is used for printing 3-D shapes. Composition of the filament is very important since it provides shape retention at low-to-medium temperature. There are a few commercially available metallic alloy filaments. However, FeCrAl alloy filaments are not commercially available. In this project, we came up with a method to fabricate high quality composite FeCrAl filaments that could be used for MEAM printing. Subsequently, we have optimized MEAM print methods to fabricate samples that are larger than 10 mm, by using a modular print design approach. Finally, we have been able to optimize the chemical and high temperature heat treatment steps to achieve very high density (>98%) in sintered MEAM-printed products.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Standard Analysis Report INV-SAR-79, Revision 0 Chemical and Cement Components 2023 Inventory Estimates

This standard analysis report provides the estimates for the chemical (oxyanions and complexing agents) and cement components with a data collection cut-off date of December 31, 2023. These estimates will be included in a Performance Assessment Inventory Report developed for the U.S. Department of Energy (DOE) performance assessment (PA) for the 2026 Compliance Recertification Application (CRA).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Standard Analysis Report INV-SAR-81, Revision 0 Chemical and Cement Components 2023 Inventory Estimates for the Interim State Performance Assessment of the Waste Isolation Pilot Plant

This standard analysis report provides the estimates for the chemical (oxyanions and complexing agents) and cement components with a data collection cut-off date of December 31, 2023. These estimates will be included in a Performance Assessment Inventory Report developed for the U.S. Department of Energy (DOE) interim state repository configuration performance assessment (PA) for the 2026 Compliance Recertification Application (CRA).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Additive Manufacturing of Leak-Free Metal Components with Thin Walls and Sealing Surfaces

Laser-powder bed fusion (L-PBF) offers the ability to print free form design components which often do not require post-processing. However, challenges arise when printing small geometries with mating surfaces. Using an AddUp FormUp 350 L-PBF machine installed at the Manufacturing Demonstration Facility (MDF) of Oak Ridge National Laboratory (ORNL), a User Agreement project was formed with intent to manufacture metal leak-free cylindrical sealing surfaces. One print of twelve 12.7mm outer diameter (OD) cylinders was designed varying wall thickness in the computer-aided design (CAD) model. A build plate was successfully printed but included two build pauses each adding about five minutes per layer. The build plate of 12 cylinders was removed from the chamber and shipped to the partner.

36 MATERIALS SCIENCE↗