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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. In conclusion, the results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

Residual stress↗
DOE OSTI2021

Distribution of Bound and Free Water in Anatomical Fractions of Pine Residues and Corn Stover as a Function of Biological Degradation

Biomass quality is influenced by water’s abundance, distribution, and status in relation to other chemical species within the polymer matrix. Water interacts with polymers that make up the cell walls, and these interactions govern the physical and chemical changes that occur during the storage and preprocessing of biomass feedstocks. Time-domain nuclear magnetic resonance (TD-NMR) was employed to explore variations in the physical constraints of water within the lignocellulosic microstructure in distinct anatomical fractions of biomass and as a function of biological degradation. The Carr–Purcell–Meiboom–Gill sequence, when combined with knowledge of the chemical composition and physical structure of pine residues and corn stover anatomical fractions, gives an accurate measurement of the bound and free water. In this work, the impacts of storage and biological degradation were investigated to elucidate changes in the status and distribution of water within distinct plant tissues. We also investigate how degradation during storage affects water interactions in different pine residues (e.g., bark, branch, and needle) and corn stover (e.g., cob, leaf, and stalk) anatomical fractions using transverse relaxation times (T2). As demonstrated herein, TD-NMR provides quantitative data on lignocellulosic biomass–water interactions within anatomical fractions, which can further aid in the investigation of preprocessing effects on feedstock quality. Our findings suggest that biological heating enhances biomass–water interactions at the cellular and macromolecular scale. In addition, analysis of three-dimensional scanning electron microscopy reconstructions indicates that surface roughness wavelengths align with microscale roughness, suggesting that pine forestry residue and corn stover particles have primarily hydrophobic exterior surfaces. Furthermore, this study offers multiscale insights into understanding the microstructure, wettability, and chemical environment that dictate diffusion, enzyme access, and recalcitrance of lignocellulosic biomass.

09 BIOMASS FUELS↗
DOE OSTI2024

Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On Residual Stresses and Reference Temperatures in Thermomechanical Simulations of Photovoltaic Modules Using the Finite Element Method

Thermomechanical simulation of photovoltaic (PV) modules using the finite element method (FEM) is a useful tool to evaluate module design features in terms of structural integrity, reliability, and durability. One of the main challenges in the numerical modeling of a PV module is the incorporation of residual stresses induced by the manufacturing process. Modeling assumptions and abstractions are necessary to limit the model complexity and reduce the computational time. However, oversimplifications and incorrect assumptions can lead to erroneous numerical results. Unfortunately, much simulation work still neglects process-induced stresses. This can lead to incorrect predictions of the stress-strain history and erroneous conclusions during the design process. In this work, we review current modeling practices for incorporating process-induced stresses, and contrast numerical models that consider residual stresses with those that neglect them. We find that the simulation objective and available material properties dictate which process steps need to be modeled, and explore in depth the modeling of residual stresses induced by the lamination process. We demonstrate that a simplified cooldown procedure at the beginning of the simulation can increase the model accuracy and discuss appropriate choices for starting and reference temperatures in the finite element model.

14 SOLAR ENERGY↗
DOE OSTI2021

Evaluation of residual gas fraction estimation methods for cycle-to-cycle combustion variability analysis and modeling

Cycle-to-cycle combustion variability in spark-ignition engines during normal operation is mainly caused by random perturbations of the in-cylinder conditions such as the flow velocity field, homogeneity of the air-fuel distribution, spark energy discharge, and turbulence intensity of the flame front. Such perturbations translate into the variability of the energy released observed at the end of the combustion process. During normal operating conditions, the cycle-to-cycle variability (CCV) of the energy release behaves as random uncorrelated noise. However, during diluted combustion, in either the form of exhaust gas recirculation (EGR) or excess air (lean operation), the CCV tends to increase as dilution increases. Moreover, when the ignition limit is reached at high dilution levels, the combustion CCV is exacerbated by sporadic occurrences of incomplete combustion events, and the uncorrelation assumption no longer holds. The low or null energy released by partial burns and misfires has an impact on the following combustion event due to the residual gas that carries burned and unburned gases, which contributes to the deterministic coupling between engine cycles. Many residual gas fraction estimation methods, however, only address the nominal case where complete combustion occurs and combustion events are uncorrelated. Here we evaluate the efficacy of such methods on capturing the effects of partial burns and misfires on the residual gas estimate for high-EGR operation. The advantages and disadvantages of each method are discussed based on their ability to generate cycle-to-cycle estimates. Finally, a comparison between the different estimation techniques is presented based on their usefulness for control-oriented modeling.

42 ENGINEERING↗
DOE OSTI2021

Dynamic life-cycle carbon analysis for fast pyrolysis biofuel produced from pine residues: implications of carbon temporal effects

Abstract Background Woody biomass has been considered as a promising feedstock for biofuel production via thermochemical conversion technologies such as fast pyrolysis. Extensive Life Cycle Assessment studies have been completed to evaluate the carbon intensity of woody biomass-derived biofuels via fast pyrolysis. However, most studies assumed that woody biomass such as forest residues is a carbon–neutral feedstock like annual crops, despite a distinctive timeframe it takes to grow woody biomass. Besides, few studies have investigated the impacts of forest dynamics and the temporal effects of carbon on the overall carbon intensity of woody-derived biofuels. This study addressed such gaps by developing a life-cycle carbon analysis framework integrating dynamic modeling for forest and biorefinery systems with a time-based discounted Global Warming Potential (GWP) method developed in this work. The framework analyzed dynamic carbon and energy flows of a supply chain for biofuel production from pine residues via fast pyrolysis. Results The mean carbon intensity of biofuel given by Monte Carlo simulation across three pine growth cases ranges from 40.8–41.2 g CO 2 e MJ −1 (static method) to 51.0–65.2 g CO 2 e MJ −1 (using the time-based discounted GWP method) when combusting biochar for energy recovery. If biochar is utilized as soil amendment, the carbon intensity reduces to 19.0–19.7 g CO 2 e MJ −1 (static method) and 29.6–43.4 g CO 2 e MJ −1 in the time-based method. Forest growth and yields (controlled by forest management strategies) show more significant impacts on biofuel carbon intensity when the temporal effect of carbon is taken into consideration. Variation in forest operations and management (e.g., energy consumption of thinning and harvesting), on the other hand, has little impact on the biofuel carbon intensity. Conclusions The carbon temporal effect, particularly the time lag of carbon sequestration during pine growth, has direct impacts on the carbon intensity of biofuels produced from pine residues from a stand-level pine growth and management point of view. The carbon implications are also significantly impacted by the assumptions of biochar end-of-life cases and forest management strategies.

09 BIOMASS FUELS↗
DOE OSTI2023

Comparative Techno-Economic Analysis of Available Feedstocks for High-Temperature Conversion: Whole Tree Thinnings and Mature Pine Residues

The TEA and LCA impacts of utilizing low-cost feedstocks in a high-temperature conversion process are of great interest. Here, we investigate the conversion cost impacts of two underutilized feedstocks from the commercial pine industry; 13-year-old whole trees, representing trees removed for the purpose of pre-commercial thinning, and 23-year-old pine residues, representing a waste stream produced from the deconstruction of mature trees for other purposes. Experimental fast pyrolysis data for each feedstock was used in tandem with results from supply and preprocessing analyses in order to evaluate the field-to-fuel economics. A low difference in MFSP was found between the conversion costs for the two feedstocks, with residues demonstrating a net benefit of $0.27/GGE compared to the whole tree thinnings, driven primarily by feedstock supply costs. This suggests that both whole tree thinnings and pine residues may be viable feedstock options for CFP conversion. Life cycle inventories were also generated for each case, enabling a field-to-fuel quantification of the cost and carbon cycle associated with each feedstock.

09 BIOMASS FUELS↗
DOE OSTI2025

National summary for agricultural crops and residues, 2041

This dataset contains national summary data on agricultural crop and residue production, which include agricultural crop, agricultural residue, herbaceous energy crop, and woody energy crop. Each tab in the Excel file contains information corresponding to a resource category, and within each tab, there is a structured table presenting resource production (in dry short ton) by offered price (in USD per dry short ton) across multiple scenarios (mature-market low, mature-market medium, and mature-market high). Consistent with the 2023 Billion-Ton report for agricultural resources, these scenarios represent potential production scenarios for 2041. List of the resources shown in this dataset: - Agricultural crop: Barley, Corn, Cotton, Grain sorghum, Hay, Oats, Rice, Soybeans, Wheat - Agricultural residue: Barley straw, Corn stover, Oats straw, Sorghum stubble, Wheat straw - Herbaceous energy crop: Biomass sorghum, Energy cane, Miscanthus, Switchgrass - Woody energy crop: Eucalyptus, Pine, Poplar, Willow

agricultural crop↗
NASA NTRS1996

Graphic Three-Axes Presentation of Residual Gas Analyser Data

Residual gas analyzers (RGA) are commonly used to measure the composition of residual gases in thermal-vacuum test chambers. Measurements from RGAs are often used to identify and quantify outgassing contaminants from a test article during thermal-vacuum testing. RGA data is typically displayed as snapshots in time, showing instantaneous concentrations of ions from ionized residual gas molecules at different atomic masses. A method was devised by the authors to present RGA data in a three-axis format, plotting atomic mass unit (AMU), ion concentration as a function of AMU, and time, to provide a clear graphic visualization ot trends in gas concentration changes and to initiate a valuable analytical tool to interpret test article outgassing rates during thermal-vacuum testing.

data analysis↗
NASA NTRS2015

The Effect of Stochastically Varying Creep Parameters on Residual Stresses in Ceramic Matrix Composites

Constituent properties, along with volume fraction, have a first order effect on the microscale fields within a composite material and influence the macroscopic response. Therefore, there is a need to assess the significance of stochastic variation in the constituent properties of composites at the higher scales. The effect of variability in the parameters controlling the time-dependent behavior, in a unidirectional SCS-6 SiC fiber-reinforced RBSN matrix composite lamina, on the residual stresses induced during processing is investigated numerically. The generalized method of cells micromechanics theory is utilized to model the ceramic matrix composite lamina using a repeating unit cell. The primary creep phases of the constituents are approximated using a Norton-Bailey, steady state, power law creep model. The effect of residual stresses on the proportional limit stress and strain to failure of the composite is demonstrated. Monte Carlo simulations were conducted using a normal distribution for the power law parameters and the resulting residual stress distributions were predicted.

residual stress↗
NASA NTRS2016

A New Load Residual Threshold Definition for the Evaluation of Wind Tunnel Strain-Gage Balance Data

A new definition of a threshold for the detection of load residual outliers of wind tunnel strain-gage balance data was developed. The new threshold is defined as the product between the inverse of the absolute value of the primary gage sensitivity and an empirical limit of the electrical outputs of a strain{gage. The empirical limit of the outputs is either 2.5 microV/V for balance calibration or check load residuals. A reduced limit of 0.5 microV/V is recommended for the evaluation of differences between repeat load points because, by design, the calculation of these differences removes errors in the residuals that are associated with the regression analysis of the data itself. The definition of the new threshold and different methods for the determination of the primary gage sensitivity are discussed. In addition, calibration data of a six-component force balance and a five-component semi-span balance are used to illustrate the application of the proposed new threshold definition to different types of strain{gage balances. During the discussion of the force balance example it is also explained how the estimated maximum expected output of a balance gage can be used to better understand results of the application of the new threshold definition.

load residuals↗
NASA NTRS2015

The Effect of Stochastically Varying Creep Parameters on Residual Stresses in Ceramic Matrix Composites

Constituent properties, along with volume fraction, have a first order effect on the microscale fields within a composite material and influence the macroscopic response. Therefore, there is a need to assess the significance of stochastic variation in the constituent properties of composites at the higher scales. The effect of variability in the parameters controlling the time-dependent behavior, in a unidirectional SCS-6 SiC fiber-reinforced RBSN matrix composite lamina, on the residual stresses induced during processing is investigated numerically. The generalized method of cells micromechanics theory is utilized to model the ceramic matrix composite lamina using a repeating unit cell. The primary creep phases of the constituents are approximated using a Norton-Bailey, steady state, power law creep model. The effect of residual stresses on the proportional limit stress and strain to failure of the composite is demonstrated. Monte Carlo simulations were conducted using a normal distribution for the power law parameters and the resulting residual stress distributions were predicted.

processing↗
NASA NTRS2022

Optimizing Landsat Next Shortwave Infrared Bands for Crop Residue Characterization

This study focused on optimizing the placement of shortwave infrared (SWIR) bands for pixel-level estimation of fractional crop residue cover (f R ) for the upcoming Landsat Next mission. We applied an iterative wavelength shift approach to a database of crop residue field spectra collected in Beltsville, Maryland, USA (n = 916) and computed generalized two- and three-band spectral indices for all wavelength combinations between 2000 and 2350 nm, then used these indices to model field-measured f R . A subset of the full dataset with a Normalized Difference Vegetation Index (NDVI) < 0.3 threshold (n = 643) was generated to evaluate green vegetation impacts on f R estimation. For the two-band wavelength shift analyses applied to the NDVI < 0.3 dataset, a generalized normalized difference using 2226 nm and 2263 nm bands produced the top f R estimation performance (R 2 = 0.8222; RMSE = 0.1296). These findings were similar to the established two-band Shortwave Infrared Normalized Difference Residue Index (SINDRI) (R 2 = 0.8145; RMSE = 0.1324). Performance of the two-band generalized normalized difference and SINDRI decreased for the full-NDVI dataset (R 2 = 0.5865 and 0.4144, respectively). For the three-band wavelength shift analyses applied to the NDVI < 0.3 dataset, a generalized ratio-based index with a 2031–2085–2216 nm band combination, closely matching established Cellulose Absorption Index (CAI) bands, was top performing (R 2 = 0.8397; RMSE = 0.1231). Three-band indices with CAI-type wavelengths maintained top f R estimation performance for the full-NDVI dataset with a 2036–2111–2217 nm band combination (R 2 = 0.7581; RMSE = 0.1548). The 2036–2111–2217 nm band combination was also top performing in f R estimation (R 2 = 0.8690; RMSE = 0.0970) for an additional analysis assessing combined green vegetation cover and surface moisture effects. Our results indicate that a three-band configuration with band centers and wavelength tolerances of 2036 nm (±5 nm), 2097 nm (±14 nm), and 2214 (±11 nm) would optimize Landsat Next SWIR bands for f R estimation.

Landsat Next↗
DOE OSTI2023

Unraveling the Mechanics: Computational Modeling of Residual Stresses in U10Mo Fuel with Aluminum Cladding

LEU (Low Enriched Uranium) plate-type fuel elements consist of a high-density, low-enrichment U–Mo alloy-based fuel foil encapsulated in an aluminum cladding and is fabricated through the Hot Isostatic Pressing (HIP) technique. Understanding the mechanism of possible failure modes of nuclear fuel is critical to mitigate potential consequences. One of the major contributing factors in various failure modes is stress and it greatly affects the integrity under temperature, pressure, and irradiation. These stresses could originate from various sources, including manufacturing, and operation, and can lead to deformation, cracking, or even complete failure of fuel elements. This study focuses on the development of a computational model that accurately predicts the residual stresses generated in the U10Mo fuel during fabrication. It has been observed that cladding creep has a substantial impact on the residual stresses in the U10Mo fuel post the HIP fabrication process. Furthermore, during the HIP bonding process the fuel plate system is heated to a temperature of 560 oC and as a result, the aluminum cladding transitions from (Al 6061-T6 to -O). This presents a challenge in capturing the change in material properties accurately. Therefore, a temperature dependent creep model such as hyperbolic sine creep model is considered to estimate the creep properties of the Aluminum cladding. The proposed calibrated creep model accurately predicts the residual stresses in the U10Mo fuel foil and agrees well with the experiments.

42 ENGINEERING↗
DOE OSTI2023

MODELS FOR ESTIMATING THE AUTOFRETTAGE PRESSURE AND RESIDUAL STRESSES IN WALLS OF TYPE 2 PRESSURE VESSELS

Autofrettage is a manufacturing process used during fabrication of Type 2 pressure vessels designed for usage at high pressures to enhance the fatigue life. The process locks high compressive residual stresses in the vessel’s liner wall that reduce the maximum and the mean stress during service loading. To achieve a consistent residual stress profile across the wall of the vessel, the choice of autofrettage pressure is critical. Several finite element analyses runs were conducted to estimate the correct autofrettage pressure that is a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner for a wrap thickness of 17.06 mm (48 wire layers). From the finite element analyses results, models were developed to estimate the correct autofrettage pressure and the residual stress distribution across the liner wall as a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner.

08 HYDROGEN↗
DOE OSTI2025

Ruthenium/Carbon Nanocomposites for Efficient Hydrogen Electrocatalysis: Impacts of Halide Residues

Ruthenium has emerged as a promising substitute for platinum toward the hydrogen evolution/oxidation reaction (HER/HOR). Herein, ruthenium/carbon composites are prepared by magnetic induction heating (300 A, 10 s) of RuCl3, RuBr3 or RuI3 loaded on hollow N-doped carbon cages (HNC). The HNC-RuCl3-300A sample consists of Ru nanoparticles (dia. 1.96 nm) and abundant Cl residues. HNC-RuBr3-300A possesses a larger nanoparticle size (≈19.36 nm) and lower content of Br residues. HNC-RuI3-300A contains only bulk-like Ru agglomerates with a minimal amount of I residues, due to reduced Ru-halide bonding interactions. Among these, HNC-RuCl3-300A exhibits the best HER activity in alkaline media, with a low overpotential of only -26 mV to reach 10 mA cm-2, even outperforming Pt/C, and can be used as the cathode catalyst for anion exchange membrane water electrolyzer (along with commercial RuO2 as the anode catalyst), producing 0.5 A cm- 2 at 1.88 V for up to 100 h, a performance markedly better than that with Pt/C. HNC-RuCl3-300A also exhibits the best HOR activity, with a half-wave potential (+18 mV) even lower than that of Pt/C (+35 mV). These activities are ascribed to the combined contributions of small Ru nanoparticles and Ru-to-halide charge transfer that weaken H adsorption.

Yu, Bingzhe↗
DOE OSTI2026

Residual symmetries and scalar multiplet vacuum alignment in non-Abelian flavour models

We demonstrate that, upon minimizing a renormalizable, single-scalar potential invariant under a non-Abelian symmetry, special orientations in the associated vacuum alignment of the scalar multiplet correspond to the preservation of a discrete residual flavour symmetry in the broken phase of the theory. Conversely, we show that these special scalar alignments are perturbed when additional Lagrangian operators (e.g. renormalizable, multi-flavon operators and/or effective, higher-dimensional operators) are present that break said residual symmetry, leading to a vacuum reorientation and phenomenological consequences. We therefore construct a one-to-one correspondence principle between broken residual symmetries and vacuum alignment corrections, providing a mechanism to identify (and correct) a subtle but persistent form of phenomenologically relevant fine-tuning embedded in — but often ignored by — most successful non-Abelian flavour models. We first establish this correspondence in a set of toy models based on the S4 permutation symmetry, and then apply the lessons learned to the more realistic A4 Altarelli-Feruglio and ∆(27) Universal Texture Zero models.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗