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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
NASA NTRS1978

Method for minimizing the cost/Watt of complete photovoltaic systems and applications

The paper describes an optimization method and some applications in which the design criterion for every part of a photovoltaic system is the minimum power cost for the complete system. The various parts of a photovoltaic system are grouped so that all costs fall into four classes: fabrication steps of the active solar cells; steps associated with the collector array and its complete structure; power-handling elements such as switchgear, storage, etc.; and fixed costs that do not vary directly with any of the system parts, such as factory-level overhead. It is assumed that the total collector area is independent of any of the optimization processes. A general equation is found to be capable of optimizing all parts of a system, although the cell and array steps are basically different from the power-handling elements. It is shown that the optimization of any step in the system requires inclusion of the properties of the other parts of the system.

Redfield, D.↗
DOE OSTI2024

Constitutive model development of aluminum alloy 1100 for elevated temperature forming process

Commercially pure aluminum alloy, AA1100, presents good electrical and thermal conductivity, high formability, and low cost. Those favorable characteristics have the potential to enable bipolar plates with improved economics and enhanced performance compared to current stainless steel bipolar plates for proton exchange membrane fuel cells. An accurate constitutive model is essential to develop and optimize processing parameters and effectively control the forming process. Here, the objective of this work is to develop a constitutive model of AA1100 that is able to simulate stress-strain relation, formed geometry, and predict the onset of fracture strain to avoid forming failure. Initially, a set of tensile tests at temperature between 300 and 500°C and strain rate between 0.005 and 1.0/s were conducted to examine the deformation behavior. Then, a set of damage-based unified visco-plastic constitutive equations is proposed and calibrated based on the results of stress-strain data. A genetic algorithm optimization method is applied to search for best fitting material constants in constitutive equations. The proposed model shows good predictability of both the stress-strain relation and fracture strain at low strain rate and high temperature conditions. The accuracy of proposed model is also evaluated statistically. A comparison of the proposed model with three popular models (Arrhenius-type mode, Johnson-Cook model and Zerilli-Armstrong model) was made. The proposed model shows the best experimental agreement with correlation coefficient of 0.96 in contrast to 0.25, 0.38 and 0.75 for the popular models, respectively. The proposed model can help to optimize the elevated temperature forming process and guide die design to enable optimal geometric features in the formed components.

08 HYDROGEN↗
NASA NTRS1990

An alternative formulation of the global sensitivity equations

To optimize the performance of any system, the sensitivity derivatives of the system's output variables with respect to its input variables must be readily available. It is also desirable that these derivatives be inexpensive to calculate as the optimization process requires many evaluations of the output variables and their derivatives. Optimization methods that have been developed for use in automated structural design programs may not be extended for use in integrated multidisciplinary design programs until adequate means of calculating accurate sensitivity derivatives of complex, internally coupled systems have been developed. Until the development of the Global Sensitivity Equations (GSE), the only method of determining the sensitivity derivatives of coupled systems has been by using finite differences. Analytical or semi-analytical derivatives do not exist as there is no analytical solution to the coupled problem. Also, difficulties arise because the finite difference method is expensive as the system has to iterate to a converged solution for each incremental input variable. The method may not be accurate, and the choice of the input variable increment may cause the difference in the output variable to be insignificant compared to computer numerical error if the choice is too small, or the process may not predict the true value of the output variable if the increment is too large. The GSE allow the system's sensitivity derivatives to be calculated as functions of the component subsystem's (local) sensitivity derivatives. These local sensitivity derivatives are calculated from specifically decoupled subsystems, whereas the GSE account for total system coupling. Since the subsystems are decoupled, it may be possible for the local derivatives to be calculated by analytical or semi-analytical methods, which generally reduce cost and improve accuracy. Several academic problems have been solved using GSE and have demonstrated encouraging results.

James, Benjamin B.↗
NASA NTRS1998

Fuzzy Adaptive Control for Intelligent Autonomous Space Exploration Problems

The principal objective of the research reported here is the re-design, analysis and optimization of our newly developed neural network fuzzy adaptive controller model for complex processes capable of learning fuzzy control rules using process data and improving its control through on-line adaption. The learned improvement is according to a performance objective function that provides evaluative feedback; this performance objective is broadly defined to meet long-range goals over time. Although fuzzy control had proven effective for complex, nonlinear, imprecisely-defined processes for which standard models and controls are either inefficient, impractical or cannot be derived, the state of the art prior to our work showed that procedures for deriving fuzzy control, however, were mostly ad hoc heuristics. The learning ability of neural networks was exploited to systematically derive fuzzy control and permit on-line adaption and in the process optimize control. The operation of neural networks integrates very naturally with fuzzy logic. The neural networks which were designed and tested using simulation software and simulated data, followed by realistic industrial data were reconfigured for application on several platforms as well as for the employment of improved algorithms. The statistical procedures of the learning process were investigated and evaluated with standard statistical procedures (such as ANOVA, graphical analysis of residuals, etc.). The computational advantage of dynamic programming-like methods of optimal control was used to permit on-line fuzzy adaptive control. Tests for the consistency, completeness and interaction of the control rules were applied. Comparisons to other methods and controllers were made so as to identify the major advantages of the resulting controller model. Several specific modifications and extensions were made to the original controller. Additional modifications and explorations have been proposed for further study. Some of these are in progress in our laboratory while others await additional support. All of these enhancements will improve the attractiveness of the controller as an effective tool for the on line control of an array of complex process environments.

Esogbue, Augustine O.↗
NASA NTRS1989

Integrated aerodynamic/dynamic optimization of helicopter rotor blades

An integrated aerodynamic/dynamic optimization procedure is used to minimize blade weight and 4 per rev vertical hub shear for a rotor blade in forward flight. The coupling of aerodynamics and dynamics is accomplished through the inclusion of airloads which vary with the design variables during the optimization process. Both single and multiple objective functions are used in the optimization formulation. The Global Criteria Approach is used to formulate the multiple objective optimization and results are compared with those obtained by using single objective function formulations. Constraints are imposed on natural frequencies, autorotational inertia, and centrifugal stress. The program CAMRAD is used for the blade aerodynamic and dynamic analyses, and the program CONMIN is used for the optimization. Since the spanwise and the azimuthal variations of loading are responsible for most rotor vibration and noise, the vertical airload distributions on the blade, before and after optimization, are compared. The total power required by the rotor to produce the same amount of thrust for a given area is also calculated before and after optimization. Results indicate that integrated optimization can significantly reduce the blade weight, the hub shear and the amplitude of the vertical airload distributions on the blade and the total power required by the rotor.

Chattopadhyay, Aditi↗
NASA NTRS2007

Topology Synthesis of Structures Using Parameter Relaxation and Geometric Refinement

Typically, structural topology optimization problems undergo relaxation of certain design parameters to allow the existence of intermediate variable optimum topologies. Relaxation permits the use of a variety of gradient-based search techniques and has been shown to guarantee the existence of optimal solutions and eliminate mesh dependencies. This Technical Publication (TP) will demonstrate the application of relaxation to a control point discretization of the design workspace for the structural topology optimization process. The control point parameterization with subdivision has been offered as an alternative to the traditional method of discretized finite element design domain. The principle of relaxation demonstrates the increased utility of the control point parameterization. One of the significant results of the relaxation process offered in this TP is that direct manufacturability of the optimized design will be maintained without the need for designer intervention or translation. In addition, it will be shown that relaxation of certain parameters may extend the range of problems that can be addressed; e.g., in permitting limited out-of-plane motion to be included in a path generation problem.

Hull, P. V.↗
DOE OSTI2025

Optimization of direct air capture processes using reactive transport models of adsorption-desorption cycles

In this study, we develop and implement a reactive transport model in COMSOL Multiphysics® to address the challenges of direct air carbon capture. The model is validated against experimental data and used to simulate the cyclic steady state of the adsorption-desorption process. The optimization of this model is achieved through advanced trust-region methods integrated with Gaussian Processes. Key decision variables, including adsorption and desorption times, desorption temperature and pressure, input velocity, bed porosity, column length, and radius were optimized to minimize the capture cost. After optimization, a sensitivity analysis revealed the complex interplay between the decision variables and their effect on the specific energy and cost of removing the CO 2 . We optimized the capture cost while taking into account the trade-off between energy consumption and productivity. The resulting minimum capture cost was determined to be 265.2 $/t-CO 2 , which aligns with expected values reported in the literature. Numerical results suggest the effectiveness of the optimization strategies applied, and underscore the importance of simultaneous decision variable selection in improving the performance in direct air capture processes. We also extend the modeling approach to a 2D axisymmetric model to better visualize CO₂ uptake and temperature profiles, revealing significant radial gradients during the regeneration step. As a main drawback, this enhanced model comes with a computational cost approximately 40 times higher than that of the 1D model.

Adsorption-desorption process↗
NASA NTRS1992

An optimal GPS data processing technique

A formula is derived to optimally combine dual-frequency GPS (Global Positioning System) pseudorange and carrier phase data streams into a single equivalent data stream, reducing the data volume and computing time in the filtering process for parameter estimation by a factor of four. The resulting single data stream is that of carrier phase measurements with both data noise and bias uncertainty strictly defined. With this analytical formula the single stream of equivalent GPS measurements can be efficiently formed by simple numerical calculations without any degradation in data strength. The formulation for the optimally combined GPS data and their covariances are given in closed form. Carrier phase ambiguity resolution, when feasible, is improved due to the preservation of the full data strength with the optimal data combining process.

Wu, S. C.↗
DOE OSTI2025

Modeling diffusion and depletion in high-aspect-ratio atomic layer deposition processes: Process parameters and manufacturing impacts

Atomic layer deposition (ALD) is a powerful technique for modifying the surface chemistry and properties of substrates with complex and nonplanar topologies. However, achieving uniform and conformal deposition on ultrahigh-aspect-ratio substrates remains challenging, typically requiring large quantities of precursors and long exposure times. Furthermore, process optimization is often performed empirically and involves substantial trial and error. In this work, we perform a combined experimental and computational study of ALD Al 2 O 3 infiltration into silica aerogel monoliths (aspect ratio >10 5 ). A reaction-diffusion model is used to explore the effects of key processing parameters, namely, exposure time per dose, precursor source temperature, number of aerogels in the reactor, and reactor volume. The model is based on quasi-static mode ALD, where the dosed precursor is held in the chamber for a fixed period of time before purging. We analyze the trade-offs between process throughput and precursor utilization for each of these parameters. Furthermore, we investigate the co-optimization and interactions between multiple process parameters, demonstrating the potential for further improvements. Furthermore, this physics-based model can be used to identify a set of process parameters for high-aspect-ratio ALD that meet specific manufacturing objective functions, including throughput, cost, and sustainability.

Aerogel↗
DOE OSTI2024

Active interlocking metasurfaces enabled by shape memory alloys

Interlocking metasurfaces (ILMs) are a newly developed joining technology that relies on arrays of interlocking features that transmit force and constrain motion between adjoining bodies in one or more directions. This study explores harnessing the shape memory effect (SME) in Nickel-Titanium shape memory alloys (NiTi SMAs) in structures fabricated using additive manufacturing (AM) to advance the development of active ILMs by creating unit cells that open or close at specific temperatures. The study encompasses designing and fabricating two distinct interlocking array configurations using near-equiatomic NiTi powder and the laser powder bed fusion (L-PBF) AM technique, following a previously developed AM process optimization framework to manufacture defect-free parts. To guide the design process, finite element analysis (FEA) was employed to predict strain values during engage-disengage cycles. The martensitic transformation characteristics of the ILMs were characterized. Thermomechanical testing revealed that the ILMs demonstrate high locking force once engaged, coupled with complete shape recovery and good cyclic stability. Digital image correlation (DIC) was also employed to validate the FEA predictions during the engage-disengage cycles. The results indicate that NiTi SMA-based ILMs can be designed and fabricated into complex shapes using L-PBF. By leveraging the SME, the functionality of an ILM can be improved upon. The combination of computational modeling, additive manufacturing, and thermomechanical and physical property characterization provides a framework for designing future ILMs out of active materials.

Additive manufacturing↗
NASA NTRS1991

Integration of dynamic, aerodynamic, and structural optimization of helicopter rotor blades

Summarized here is the first six years of research into the integration of structural, dynamic, and aerodynamic considerations in the design-optimization process for rotor blades. Specifically discussed here is the application of design optimization techniques for helicopter rotor blades. The reduction of vibratory shears and moments at the blade root, aeroelastic stability of the rotor, optimum airframe design, and an efficient procedure for calculating system sensitivities with respect to the design variables used are discussed.

Peters, David A.↗
NASA NTRS1994

JPL-ANTOPT antenna structure optimization program

New antenna path-length error and pointing-error structure optimization codes were recently added to the MSC/NASTRAN structural analysis computer program. Path-length and pointing errors are important measured of structure-related antenna performance. The path-length and pointing errors are treated as scalar displacements for statics loading cases. These scalar displacements can be subject to constraint during the optimization process. Path-length and pointing-error calculations supplement the other optimization and sensitivity capabilities of NASTRAN. The analysis and design functions were implemented as 'DMAP ALTERs' to the Design Optimization (SOL 200) Solution Sequence of MSC-NASTRAN, Version 67.5.

Strain, D. M.↗
NASA NTRS2017

A Requirements-Driven Optimization Method for Acoustic Liners Using Analytic Derivatives

More than ever, there is flexibility and freedom in acoustic liner design. Subject to practical considerations, liner design variables may be manipulated to achieve a target attenuation spectrum. But characteristics of the ideal attenuation spectrum can be difficult to know. Many multidisciplinary system effects govern how engine noise sources contribute to community noise. Given a hardwall fan noise source to be suppressed, and using an analytical certification noise model to compute a community noise measure of merit, the optimal attenuation spectrum can be derived using multidisciplinary systems analysis methods. In a previous paper on this subject, a method deriving the ideal target attenuation spectrum that minimizes noise perceived by observers on the ground was described. A simple code-wrapping approach was used to evaluate a community noise objective function for an external optimizer. Gradients were evaluated using a finite difference formula. The subject of this paper is an application of analytic derivatives that supply precise gradients to an optimization process. Analytic derivatives improve the efficiency and accuracy of gradient-based optimization methods and allow consideration of more design variables. In addition, the benefit of variable impedance liners is explored using a multi-objective optimization.

Aircraft Noise↗
DOE OSTI2024

A comparative analysis of residual stresses from friction stir processing of aluminum cast 380 and wrought 7075 alloy sheets: experimental characterization and modeling

Residual stresses are often overlooked in friction stir processing (FSP), but their significant impact on fatigue performance necessitates their consideration in optimizing processing parameters. The first step in this effort is understanding how process conditions influence residual stress distributions, especially across different alloys. This study focuses on determining and explaining the through-thickness residual stress variations and the effect of process temperature on the residual stress magnitude in wrought AA7075 and cast AA380.0 alloys. Additionally, for AA380.0, the impact of a second FSP pass was investigated. To achieve this, hole-drilling electronic speckle pattern interferometry (ESPI) and the thermal pseudo-mechanical (TPM) model within finite element analysis were employed to study the 3D distributions of in-plane residual stresses in processed samples under various conditions. A key finding was the varying impact of process temperatures on residual stress magnitudes. Higher process temperatures reduced stresses in AA380.0 but increased them in AA7075. Additionally, the through-thickness stress distributions differed between the two alloys. Further analysis revealed that yield stresses are crucial in explaining these phenomena and the effects of additional FSP passes. Further, this fundamental understanding will be vital in guiding the efforts to mitigate residual stresses and assess their impact on the performance of FSP aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Metal additive manufacturing simulation across length, time, and computing scales

Metal additive manufacturing (AM) offers a unique opportunity for production of advanced materials and complex geometries. However, variability in microstructure and properties challenges conventional approaches to design, process optimization, qualification, and materials selection. Modeling and simulation can improve understanding of AM processing and materials, but also poses major challenges for existing computational methods. Simultaneously, modern scientific computing hardware has become increasingly complex, most notably with the adoption of hybrid architectures such as Graphical Processing Units (GPUs). If appropriately utilized, emerging computational capabilities provide an opportunity to reveal new insight into AM processing and the resulting material structure and properties. In this review we describe the computational AM landscape, identify critical gaps, and highlight opportunities to impact the development and application of AM. First, the requirements and challenges of representative AM problem statements will be defined. Here, these problems range from scientific studies to industrial applications and are designed to capture the breadth of challenges facing the AM community. Next, the current state of AM modeling and simulation is evaluated, broken down by enabling hardware and software, process simulation, microstructure simulation, and property simulation. Each section describes the diversity of simulation approaches and associated trade-offs in physical fidelity and computational expense. Each area is then assessed based on their suitability and readiness for current and developing computational architectures. Lastly, the greatest opportunities for future research and application are highlighted, including gaps in modeling capabilities, opportunities for near-term application, and key scientific challenges.

additive manufacturing↗
NASA NTRS1979

Application of numerical optimization to the design of advanced supercritical airfoils

An application of numerical optimization to the design of advanced airfoils for transonic aircraft showed that low-drag sections can be developed for a given design Mach number without an accompanying drag increase at lower Mach numbers. This is achieved by imposing a constraint on the drag coefficient at an off-design Mach number while minimizing the drag coefficient at the design Mach number. This multiple design-point numerical optimization has been implemented with the use of airfoil shape functions which permit a wide range of attainable profiles during the optimization process. Analytical data for the starting airfoil shape, a single design-point optimized shape, and a double design-point optimized shape are presented. Experimental data obtained in the NASA Ames two-by two-foot wind tunnel are also presented and discussed.

Johnson, R. R.↗
NASA NTRS1989

Transonic airfoil design for helicopter rotor applications

Despite the fact that the flow over a rotor blade is strongly influenced by locally three-dimensional and unsteady effects, practical experience has always demonstrated that substantial improvements in the aerodynamic performance can be gained by improving the steady two-dimensional charateristics of the airfoil(s) employed. The two phenomena known to have great impact on the overall rotor performance are: (1) retreating blade stall with the associated large pressure drag, and (2) compressibility effects on the advancing blade leading to shock formation and the associated wave drag and boundary-layer separation losses. It was concluded that: optimization routines are a powerful tool for finding solutions to multiple design point problems; the optimization process must be guided by the judicious choice of geometric and aerodynamic constraints; optimization routines should be appropriately coupled to viscous, not inviscid, transonic flow solvers; hybrid design procedures in conjunction with optimization routines represent the most efficient approach for rotor airfroil design; unsteady effects resulting in the delay of lift and moment stall should be modeled using simple empirical relations; and inflight optimization of aerodynamic loads (e.g., use of variable rate blowing, flaps, etc.) can satisfy any number of requirements at design and off-design conditions.

Hassan, Ahmed A.↗
NASA NTRS1989

Robust eigenstructure assignment by a projection method - Applications using multiple optimization criteria

A methodology for robust eigenstructure assignment for multivariable feedback systems is presented. The algorithm is based upon a pole placement technique using projections onto subspaces of admissible eigenvectors. New ideas are introduced to generate target (desired) sets of unitary eigenvectors and determine optimal feasible eigenvectors in a least-square sense. Useful connections are established between the pole-placement by independent modal space control and the method introduced in this paper. A multicriterion optimization algorithm is also presented, which takes efficient advantage of the present eigenstructure assignment method. These developments show significant improvement over an earlier version of this algorithm in both computational cost and accuracy. This optimization process appears to be numerically robust and suitable for high-dimensional multicriterion optimizations; it is especially attractive for computer-aided design of control systems.

Rew, D. W.↗