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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 289 records · Page 16

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Gradl, Paul↗

Machine Learning Techniques for Data Reduction of Climate Applications

Scientists conduct large-scale simulations to compute derived quantities-of-interest (QoI) from primary data. Often, QoI are linked to specific features, regions, or time intervals, such that data can be adaptively reduced without compromising the integrity of QoI. For many spatiotemporal applications, these QoI are binary in nature and represent presence or absence of a physical phenomenon. We present a pipelined compression approach that first uses neural-network-based techniques to derive regions where QoI are highly likely to be present. Then, we employ a Guaranteed Autoencoder (GAE) to compress data with differential error bounds. GAE uses QoI information to apply low-error compression to only these regions. This results in overall high compression ratios while still achieving downstream goals of simulation or data collections. Experimental results are presented for climate data generated from the E3SM Simulation model for downstream quantities such as tropical cyclone and atmospheric river detection and tracking. These results show that our approach is superior to comparable methods in the literature.

Li, Xiao [University of Florida]↗

Pass-transistor very large scale integration

Logic elements are provided that permit reductions in layout size and avoidance of hazards. Such logic elements may be included in libraries of logic cells. A logical function to be implemented by the logic element is decomposed about logical variables to identify factors corresponding to combinations of the logical variables and their complements. A pass transistor network is provided for implementing the pass network function in accordance with this decomposition. The pass transistor network includes ordered arrangements of pass transistors that correspond to the combinations of variables and complements resulting from the logical decomposition. The logic elements may act as selection circuits and be integrated with memory and buffer elements.

Maki, Gary K.↗

Modification in drag of turbulent boundary layers resulting from manipulation of large-scale structures

The effects of placing a parallel-plate turbulence manipulator in a boundary layer are documented through flow visualization and hot wire measurements. The boundary layer manipulator was designed to manage the large scale structures of turbulence leading to a reduction in surface drag. The differences in the turbulent structure of the boundary layer are summarized to demonstrate differences in various flow properties. The manipulator inhibited the intermittent large scale structure of the turbulent boundary layer for at least 70 boundary layer thicknesses downstream. With the removal of the large scale, the streamwise turbulence intensity levels near the wall were reduced. The downstream distribution of the skin friction was also altered by the introduction of the manipulator.

Corke, T. C.↗

Incorporating energy justice into utility-scale photovoltaic deployment: A policy framework

Utility-scale photovoltaic (PV) installations made up 77 GW (6%) of installed capacity in the United States, as of the end of 2021. This will grow to more than 500 GW by 2050 under a mid-case projection or more than 800 GW if solar costs decline more rapidly. While utility-scale PV is projected to grow rapidly, to date, unlike energy efficiency or distributed PV, utility-scale PV has not been used to provide substantial financial benefits to underserved communities, either through ownership, financing of assets, or direct electricity bill reduction. We assess two mechanisms through which utility-scale PV could benefit underserved communities. We find that while a framework for direct electricity bill reduction can be meaningful to customers, this mechanism falls short of providing restorative justice via wealth creation for minority-owned businesses. In contrast, we find that a framework for procurement of utility-scale PV by public and private entities from PV projects that are financed, owned, and/or developed by minority-owned businesses can provide this restorative justice benefit, and thereby facilitate an equitable energy transition. We conclude with concrete recommendations for new policies and programs to ensure that the benefits of utility-scale PV systems are distributed to underserved communities.

14 SOLAR ENERGY↗

S-OPT: A Points Selection Algorithm for Hyper-Reduction in Reduced Order Models

While projection-based reduced order models can reduce the dimension of full order solutions, the resulting reduced models may still contain terms that scale with the full order dimension. Hyper-reduction techniques are sampling-based methods that further reduce this computational complexity by approximating such terms with a much smaller dimension. The goal of this work is to introduce the points selection algorithm developed by Shin and Xiu as a hyper-reduction method. The selection algorithm was originally proposed as a stochastic collocation method for uncertainty quantification. Since the algorithm aims at maximizing a quantity $\mathcal{S}$ that measures both the column orthogonality and the determinant, we refer to the algorithm as S-OPT. Numerical examples are provided to demonstrate the performance of S-OPT and to compare its performance with a gappy proper orthogonal decomposition (POD) algorithm. Here, we found that using the S-OPT algorithm is shown to predict the full order solutions with higher accuracy than gappy POD especially when the number of sampling points is small, although we note that S-OPT shows slow asymptotic convergence with respect to the number of samples for some applications, e.g., Lagrangian hydrodynamics.

97 MATHEMATICS AND COMPUTING↗

Noise, Turbulence, and Thrust of Subsonic Free Jets from Lobed Nozzles

A study of noise benefit, vis-a-vis thrust penalty, and its correlation to turbulence intensities was conducted for free jets issuing from lobed nozzles. Four convergent nozzles with constant exit area were used in the experiments. Three of these were of rectangular lobed configuration having six, ten and fourteen lobes; the fourth was a circular nozzle. Increasing the number of lobes resulted in a progressive reduction in the turbulence intensities as well as in the overall radiated noise. The noise reduction was pronounced at the low frequency end of the spectrum. However, there was an increase in the high frequency noise that rendered the overall benefit less attractive when compared on a scaled-up A-weighted basis. A reduction in noise was accompanied by a commensurate reduction in the turbulent kinetic energy in the flow field. As expected, increasing the number of lobes involved progressive reduction in the thrust coefficient. Among the cases studied, the six-lobed nozzle had the optimum reduction in turbulence and noise with the least thrust penalty.

Zaman, K. B. M. Q.↗

Variational nonlinear WKB in the Eulerian frame

Nonlinear WKB is a multiscale technique for studying locally plane-wave solutions of nonlinear partial differential equations (PDEs). Its application comprises two steps: (1) replacement of the original PDE with an extended system separating the large scales from the small and (2) reduction of the extended system to its slow manifold. In the context of variational fluid theories with particle relabeling symmetry, nonlinear WKB in the mean Eulerian frame is known to possess a variational structure. This much has been demonstrated using, for instance, the theoretical apparatus known as the generalized Lagrangian mean. On the other hand, the variational structure of nonlinear WKB in the conventional Eulerian frame remains mysterious. By exhibiting a variational principle for the extended equations from step (1) above, here we demonstrate that nonlinear WKB in the Eulerian frame is in fact variational. Remarkably, the variational principle for the extended system admits loops of relabeling transformations as a symmetry group. Noether’s theorem therefore implies that the extended Eulerian equations possess a family of circulation invariants parameterized by S 1 . As an illustrative example, we use our results to systematically deduce a variational model of high-frequency acoustic waves interacting with a larger-scale compressible isothermal flow.

97 MATHEMATICS AND COMPUTING↗

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗

Performance study of charcoal-based radon reduction systems for ultraclean rare event detectors

The continuous emanation of radon due to trace amounts of uranium and thorium in detector materials introduces radon to the active detection volume of low-background rare event search detectors. 222 Rn produces a particularly problematic background in the physics region of interest by the "naked" beta decay of its 214 Pb daughter nucleus. While charcoal-based adsorption traps are expected to be effective for radon reduction in auxiliary circulation loops that service the warm components of current ton-scale detectors at slow flow rates (0.5-2 SLPM), radon reduction in the entire circulation loop at high flow rates $\mathcal{O}$(100s SLPM) is necessary to reach high sensitivity in future generation experiments. In this article we explore radon dynamics with a charcoal-based radon reduction system in the main circulation loop of time projection chamber detectors. Here, we find that even for perfect radon traps, circulation speeds of 2,000 SLPM are needed to reduce radon concentration in a 10 ton detector by 90%. This is faster by a factor of four than the highest circulation speeds currently achieved in dark matter detectors. We further find that the effectiveness of vacuum swing adsorption systems, which have been employed very successfully at reducing atmospheric radon levels in clean-rooms, is limited by the intrinsic radon activity of the charcoal adsorbent in ultra-low radon environments. Adsorbents with significantly lower intrinsic radon activity than in currently available activated charcoals would be necessary to build effective vacuum swing adsorption systems operated at room temperature for rare event search experiments. If such VSA systems are cooled to about 190 K, this requirement relaxes drastically.

47 OTHER INSTRUMENTATION↗

An assessment of the utility of multirate time integration for the modeling of laser powder bed fusion

Finite element simulation of the laser powder bed fusion process is made challenging by the inherently multiscale nature of the process. When using the typical global time stepping techniques, slowly-evolving regions of the domain receive the same numerical treatment as the regions with the highest temperature rates. The current work details the implementation and evaluation of an implicit multirate method which is able to advance different regions of the domain with distinct time steps, depending on their current solution rate. Previous work indicates that this representation of the temporal scales of the problem can lead to significant reductions in wall clock run time, and it is shown herein that multirate time integration, when used with a uniform process-scale mesh, can result in speedups of approximately 19, 42, and 87 times, for domains with edge lengths of approximately 1 mm, 2 mm, and 5 mm, respectively. When used in conjunction with $\ h$-refinement (limited to two levels of refinement), the resulting speedups (taken relative to the uniform mesh) are around 28, 85, and 665 times. The method is demonstrated to converge as indicated by the literature, and its use with an AM-Bench domain is demonstrated.

42 ENGINEERING↗

Radar backscattering from a sea having an anisotropic large-scale surface, part 2

A two scale scattering model was derived that combines specular reflections from sea waves and Bragg scattering in a manner consistent with energy conservation. The effect of the tilting of the small scale roughness by the large scale roughness was included, which accounted for the reduction of reflected power. The special case of backscattering for which the transmitted polarization equaled the received polarization was considered. An anisotropic large scale surface was used to specify the probability density function of the large scale surface normal. In order to isolate the azimuthal variation of the normalized radar cross section produced by the anisotropic probability density function, an isotropical small scale spectrum was assumed.

Wentz, F. J.↗

Reduction and analysis of satellite magnetometer data

The broad-scale magnetic anomalies that appear in regional complications of aeromagnetic data, and in regional and global maps are discussed. Satellite data can be of value in defining such anomalies and invaluable, especially when utilized with airborne data, in their interpretation. The reduction and interpretation of satellite magnetometer data differ significantly from the standard techniques that are routinely applied to conventional measurements. The reduction of the data is discussed and its morphology is detailed. Interpretational techniques that are applicable are presented.

Regan, R. D.↗

Atomically Revealing Bulk Point Defect Dynamics in Hydrogen‐Driven γ‐Fe 2 O 3 → Fe 3 O 4 → FeO Transformation

Understanding how point defects in the bulk govern redox transformations is essential for advancing hydrogen-based metal production and designing high-performance oxide materials. This study reveals the atomic-scale mechanisms driving hydrogen-induced reduction of γ-Fe 2 O 3 to Fe 3 O 4 , focusing on how bulk vacancy dynamics dictate structural evolution and reaction kinetics. A key finding is the pronounced contrast in defect behavior between the two oxides: in γ-Fe 2 O 3 , intrinsic Fe vacancies promote oxygen vacancy clustering, destabilizing the local lattice and driving nanopore formation. In contrast, Fe 3 O 4 exhibits a higher oxygen vacancy formation energy and lacks intrinsic Fe vacancies, suppressing vacancy aggregation and maintaining a dense, pore-free structure. This divergence governs distinct reduction pathways—γ-Fe 2 O 3 undergoes an interface-reaction-limited transformation confined to the γ-Fe 2 O 3 /Fe 3 O 4 boundary, while Fe 3 O 4 supports a uniform increase in oxygen vacancy concentration, enabling bulk-phase reduction to lower-oxide FeO. Integrated in situ electron microscopy and density functional theory modeling uncover a vacancy-mediated mechanism, where synergistic cation-anion vacancy dynamics steer microstructure evolution and phase progression. These insights highlight the critical role of vacancy dynamics in controlling oxide reactivity and offer a pathway toward vacancy engineering to enhance reduction kinetics in hydrogen metallurgy and to tailor porosity, reactivity, and structural resilience in oxide-based catalysts and energy materials.

36 MATERIALS SCIENCE↗

Nonlinear multiobjective and dynamic real-time predictive optimization for optimal operation of baseload power plants under variable renewable energy

Considering the increase of disruptive variable renewable energy penetration into the power grid, this article focuses on the investigation of a multiobjective and dynamic real-time optimization framework to address the cycling of large-scale power plants under renewable penetration. In this framework, a parallelized particle swarm optimization step is first performed to generate feasible initial points. Then, a multiobjective and dynamic real-time optimization formulation generates optimal trajectories. Further, the benefit of predictive capability is investigated for the dynamic component, which introduces the novel nonlinear multiobjective and dynamic real-time predictive optimization approach. Two multiobjective formulations to obtain Pareto front optimal in real time are explored: the modified Tchebycheff-based weighted metric and ϵ-constraint methods. Economic and environmental objectives are considered in this study. A novel topical discussion on the intersection of dynamic real-time optimization with model predictive control is also presented. The developed framework is successfully applied to a baseload coal-fired power plant with postcombustion CO 2 capture. Results indicate that the approach can be deployed for a large-scale system if automatic differentiation, model reduction, and parallelization are adopted to improve computational tractability, with computational improvement up to 120-folds after performing these steps. Finally, market and carbon policies showed an impact on the optimal compromise between the objectives with an additional 63 ton of CO 2 captured under favorable market conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Long-term carbon intensity reduction potential of K-12 school buildings in the United States

School buildings have a great potential for carbon emission reduction since their annual emission is about 72 million metric tons. Currently, more than 30% of school buildings were built before 1960 and are underperforming. To effectively reduce carbon emissions via school building retrofits, it is critical for policymakers to understand the carbon intensity reduction potential of retrofitting school buildings in different regions. Hence, this study develops a method to comprehensively assess the long-term carbon intensity reduction potential of aggregated commercial buildings on a county-by-county basis in the continental U.S. We apply this method to the K-12 school buildings including primary and secondary school buildings. Here, this paper predicts the carbon intensity reduction potential of K-12 school buildings with eight building retrofit measures from 2022 to 2050 in the continental U.S. The results reveal several interesting findings: (1) In the approximately 3,000 counties of the U.S. from 2022 to 2050, the carbon intensity reduction potential of retrofitting K-12 school buildings in each county ranges from 0.41 kg/m 2 to 40.00 kg/m 2 . (2) Even in the same climate zone, the trends of carbon intensity reduction potential from 2022 to 2050 are different depending on their electricity sources. For example, in a hot and humid climate zone, the carbon intensity reduction potential in Florida will decrease from 2044 to 2048. However, in Mississippi, the carbon intensity reduction potential from 2044 to 2046 will increase due to the termination of the nuclear energy usage. (3) Generally, reducing lighting power density leads to more carbon intensity reduction in most states, but it might not be applicable for states with high clean energy penetration, such as Washington.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Ku-band electron linac for battery-powered hand-portable 2-MeV X-ray generator

X-ray generators, producing radiation in MeV range, are a critical tool for radiography, non-destructive testing and security applications. Field operation of such source requires them to be hand-portable, autonomous and allow parameter adjustability. RF linear accelerators can serve as a flexible, reliable, and robust radiation generator alternative to dangerous radioisotopes and bulky betatrons that are currently used for field radiography if their size, weight, cost, and imaging performance are matched to these sources. Here, in this paper, we present the design and test results of a 2 MeV Ku-band electron linac for a hand-portable X-ray generator system for field radiography being developed by RadiaBeam. The dramatic scale of miniaturization and cost-reduction is achieved thanks to the implementation of innovative technologies such as air-cooled Ku-band air-traffic control magnetrons, a split accelerating structure fabrication technique, and solid-state Marx modulators. This paper presents the design of the first prototype of the accelerator, its operation from Li-Ion batteries, as well as high-power and beam measurements.

43 PARTICLE ACCELERATORS↗