Search NASA⌕ Search

SEARCH · Search NASA

Results for “Engineering prototypes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Principle Findings from Development of a Recirculated Exhaust Gas Intake Sensor (REGIS) Enabling Cost-Effective Fuel Efficiency Improvement

Kick-off of the Bosch scope of work for the REGIS project started in October 2012. The primary work-packages included in the Bosch scope of work were the following: overall project management, development of the EGR sensor (design of sensor element, design of protection tube, and design of mounting orientation), development of EGR system control strategy, build-up of prototype sensors, evaluation of system performance with the new sensor and the new control strategy, long-term durability testing, and development of a 2nd generation sensor concept for continued technology development after the REGIS project. The University of Clemson was a partner with Bosch in the REGIS project. The Clemson scope of work for the REGIS project started in June 2013. The primary work-packages included in the Clemson scope of work were the following: development of EGR system control strategy, and evaluation of system performance with the new sensor and new control strategy. This project was split into phase I, phase II and phase III. Phase I work was completed by the end of June 2014 and included the following primary work packages: development of sensor technical requirements, assembly of engine testbench at Clemson, design concept for sensor housing, connector, and mounting orientation, build-up of EGR flow test benches at Bosch, and build-up of first sensor prototypes. Phase II work was completed by the end of June 2015 and included the following primary work pack ages: development of an optimizing function and demonstration of robustness of sensor, system control strategy implementation and initial validation, completion of engine in the loop testing of developed control algorithm, completion of sensor testing including characteristic line, synthetic gas test stand, and pressure dependency characterization, demonstration of benefits of control w/o sensing via simulation, development of 2nd generation sensor concept. Notable technical achievements from phase II were the following: publication of two new technical papers by Clemson detailing the control strategies used for the EGR system control. The two papers was published in the 2016 SAE World Congress in April 2016. The titles of each paper are, “Physics-Based Exhaust Pressure and Temperature Estimation for Low Pressure EGR Control in Turbocharged Gasoline Engines,” by K. Siokos, and “A Control Algorithm for Low Pressure – EGR Systems using a Smith Predictor with Intake Oxygen Sensor Feedback”, by R. Koli. All phase III work packages have been completed. The primary work packages in phase III were the following: completion of long-term sensor durability testing, final demonstration of benefits of EGR control w/o sensing, final decision of the second generation sensor development path.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

NDT System for Metal Components in Concrete Structures (Final Report)

Steel reinforcements embedded within concrete can corrode and crack, leading to weakening of the structures, and existing NDT (non-destructive testing) techniques do not provide the full picture. Condition assessment is critical in evaluating these structures in order to ensure safe, long-term operation of the nuclear power plants. Improved NDT techniques are needed as the nation’s generating stations age and require action based on increasingly critical inspection data. The power industry uses eddy current test (ECT) during in-service inspections to detect and monitor defects such as cracks and corrosion in metals, particularly metal pipes. However, the detection of defects in the reinforcing steel embedded in concrete is far more challenging for numerous reasons. Primary among them is the concrete layer’s thickness, which prevents the ability to have a close proximity between sensor and metallic sample. One solution to this problem is to create a higher sensitivity technique which can inspect at depth, with good spatial resolution and excellent directional sensitivity, to isolate the metal buried deep in the concrete and characterize defects in the metal. The goal of the phase II research program was to study and develop a new reinforced concrete NDT technology based on anisotropic magnetoresistive (AMR) sensors designed specifically for ECT of steel reinforcements in concrete. The first technical objective was to demonstrate the capability of inspecting steel reinforcement structures, including metal rebar and tensioning cable at or below 6” of depth embedded in concrete. Another objective was to be able to confidently identify multiple layers of reinforcements at varying depths. In addition, the technique needed to be able to provide condition assessment of the metal, providing data on the structure and positioning of the steel members, material loss, and detection of the presence of breaks. An important part of the research and development was aimed at achieving superior performance compared to existing technology. The ability to detect corrosion breaks in unbonded multi-wire and multi-strand tendons was another important objective. The final objective that led to a successful program was to build a complete prototype portable scanning system capable of demonstrating the probe performance in the field. All of these objectives were met, which provided data for the system development work going forward. RMD worked with the engineering firm Simpson Gumpertz & Heger to develop a detailed problem definition for concrete structures and the necessary sensor specifications. In addition, we developed finite element simulation models for the eddy current based NDT system through the analysis of the electromagnetic (EM) properties of sample materials and the orientation of the transmitter, sensor array (receivers), metal, and intervening materials like concrete and air. Based on the modeling and specifications, we designed and fabricated prototype sensor modules. We then acquired and fabricated test samples to characterize and optimize the sensors. Finally, we built a complete prototype for testing on actual concrete structures. This new NDT technology has high promise for greatly improving capabilities in the inspection of steel reinforcements within concrete structures, such as rebar, liners, anchors, and prestressing cables. This method could be valuable in the maintenance of nuclear power plants, and many other structures critical to our nation’s infrastructure.

42 ENGINEERING↗
DOE OSTI2016

Produced Water Treatment Using the Switchable Polarity Solvent Forward Osmosis (SPS FO) Desalination Process: Preliminary Engineering Design Basis

Switchable Polarity Solvent Forward Osmosis (SPS FO) is a semi-permeable membrane-based water treatment technology. INL is currently advancing SPS FO technology such that a prototype unit can be designed and demonstrated for the purification of produced water from oil and gas production operations. The SPS FO prototype unit will used the thermal energy in the produced water as a source of process heat, thereby reducing the external process energy demands. Treatment of the produced water stream will reduce the volume of saline wastewater requiring disposal via injection, an activity that is correlated with undesirable seismic events, as well as generate a purified product water stream with potential beneficial uses. This paper summarizes experimental data that has been collected in support of the SPS FO scale-up effort, and describes how this data will be used in the sizing of SPS FO process equipment. An estimate of produced water treatment costs using the SPS FO process is also provided.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Preparation of Smart Materials by Additive Manufacturing Technologies: A Review

Over the last few decades, advanced manufacturing and additive printing technologies have made incredible inroads into the fields of engineering, transportation, and healthcare. Among additive manufacturing technologies, 3D printing is gradually emerging as a powerful technique owing to a combination of attractive features, such as fast prototyping, fabrication of complex designs/structures, minimization of waste generation, and easy mass customization. Of late, 4D printing has also been initiated, which is the sophisticated version of the 3D printing. It has an extra advantageous feature: retaining shape memory and being able to provide instructions to the printed parts on how to move or adapt under some environmental conditions, such as, water, wind, light, temperature, or other environmental stimuli. This advanced printing utilizes the response of smart manufactured materials, which offer the capability of changing shapes postproduction over application of any forms of energy. The potential application of 4D printing in the biomedical field is huge. Here, the technology could be applied to tissue engineering, medicine, and configuration of smart biomedical devices. Various characteristics of next generation additive printings, namely 3D and 4D printings, and their use in enhancing the manufacturing domain, their development, and some of the applications have been discussed. Special materials with piezoelectric properties and shape-changing characteristics have also been discussed in comparison with conventional material options for additive printing.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cell-free biosynthesis of limonene using enzyme-enriched Escherichia coli lysates

Abstract Isoprenoids are an attractive class of metabolites for enzymatic synthesis from renewable substrates. However, metabolic engineering of microorganisms for monoterpenoid production is limited by the need for time-consuming, and often non-intuitive, combinatorial tuning of biosynthetic pathway variations to meet design criteria. Towards alleviating this limitation, the goal of this work was to build a modular, cell-free platform for construction and testing of monoterpenoid pathways, using the fragrance and flavoring molecule limonene as a model. In this platform, multiple Escherichia coli lysates, each enriched with a single overexpressed pathway enzyme, are mixed to construct the full biosynthetic pathway. First, we show the ability to synthesize limonene from six enriched lysates with mevalonate substrate, an adenosine triphosphate (ATP) source, and cofactors. Next, we extend the pathway to use glucose as a substrate, which relies on native metabolism in the extract to convert glucose to acetyl-CoA along with three additional enzymes to convert acetyl-CoA to mevalonate. We find that the native E. coli farnesyl diphosphate synthase (IspA) is active in the lysate and diverts flux from the pathway intermediate geranyl pyrophospahte to farnesyl pyrophsophate and the byproduct farnesol. By adjusting the relative levels of cofactors NAD+, ATP and CoA, the system can synthesize 0.66 mM (90.2 mg l−1) limonene over 24 h, a productivity of 3.8 mg l−1 h−1. Our results highlight the flexibility of crude lysates to sustain complex metabolism and, by activating a glucose-to-limonene pathway with 9 heterologous enzymes encompassing 20 biosynthetic steps, expands an approach of using enzyme-enriched lysates for constructing, characterizing and prototyping enzymatic pathways.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2015

Synthetic methylotrophy: engineering the production of biofuels and chemicals based on the biology of aerobic methanol utilization

Synthetic methylotrophy is the development of non-native methylotrophs that can utilize methane and methanol as sole carbon and energy sources or as co-substrates with carbohydrates to produce metabolites as biofuels and chemicals. Here, the availability of methane (from natural gas) and its oxidation product, methanol, has been increasing, while prices have been decreasing, thus rendering them as attractive fermentation substrates. As they are more reduced than most carbohydrates, methane and methanol, as co-substrates, can enhance the yields of biologically produced metabolites. Here we discuss synthetic biology and metabolic engineering strategies based on the native biology of aerobic methylotrophs for developing synthetic strains grown on methanol, with Escherichia coli as the prototype.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Architecting the Third Dimension of Electrochemical Energy Storage

Three-dimensional (3D) architectural design has emerged as a powerful strategy to push electrochemical energy storage (EES) devices beyond the intrinsic limitations of conventional two-dimensional (2D) electrodes. While planar architectures enable high packing density and mature manufacturing, they suffer from limited ion transport and low active-material loading. In contrast, 3D architectures introduce low-tortuosity networks and high surface area that enhance charge and mass transport while supporting thick, high mass-loading electrodes. However, their practicality remains hindered by challenges in volumetric density, mechanical stability, and large-scale manufacturability. Here, this Perspective examines the key evaluation and design principles that govern 3D device performance. We discuss the fundamental trade-offs between porosity, volumetric density, and mechanical stability that shape 3D design and highlight emerging strategies for integrating materials engineering, structural optimization, device integration, computational modeling, and scalable manufacturing. By aligning structural functionality with manufacturability, 3D architectures can evolve from laboratory prototypes to commercially viable energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2015

Reliability and availability requirements analysis for DEMO: fuel cycle system

The Demonstration Power Plant (DEMO) will be a fusion reactor prototype designed to demonstrate the capability to produce electrical power in a commercially acceptable way. Two of the key elements of the engineering development of the DEMO reactor are the definitions of reliability and availability requirements (or targets). The availability target for a hypothesized Fuel Cycle has been analysed as a test case. The analysis has been done on the basis of the experience gained in operating existing tokamak fusion reactors and developing the ITER design. Plant Breakdown Structure (PBS) and Functional Breakdown Structure (FBS) related to the DEMO Fuel Cycle and correlations between PBS and FBS have been identified. At first, a set of availability targets has been allocated to the various systems on the basis of their operating, protection and safety functions. 75% and 85% of availability has been allocated to the operating functions of fuelling system and tritium plant respectively. 99% of availability has been allocated to the overall systems in executing their safety functions. The chances of the systems to achieve the allocated targets have then been investigated through a Failure Mode and Effect Analysis and Reliability Block Diagram analysis. The following results have been obtained: 1) the target of 75% for the operations of the fuelling system looks reasonable, while the target of 85% for the operations of the whole tritium plant should be reduced to 80%, even though all the tritium plant systems can individually reach quite high availability targets, over 90% - 95%; 2) all the DEMO Fuel Cycle systems can reach the target of 99% in accomplishing their safety functions. (authors)

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Automated Mini-Tubular Ceramic Production (Final Design Review)

Researchers at Lawrence Livermore National Laboratory need a way to increase the rate of manufacturing of mini-tubular ceramics to be used in testing particulate air filters. This document outlines our process from researching and writing an initial scope of work all the way to fabricating and testing a final prototype. This journey takes us through the background research, ideation process and selection of a final design. We also detail the desired engineering specifications and our concept selection process. We dedicate a significant portion of this report to discussion of our final design. We delve into how it was manufactured as well as the tests we performed and its successes and failures. We also propose potential areas for further development and next steps for sponsors. Overall, this document provides the reader with a comprehensive understanding of our design process and results.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Centipod WEC Design for PacWave (Final Technical Report)

This project developed a Wave Energy Converter (WEC) system design that was ready for fabrication, deployment, and prototype testing at PacWave. The WEC design incorporated the International Electrotechnical Commission (IEC) Technical Specifications (TS) and Institute of Electrical and Electronics Engineers (IEEE) standards to ensure that designs are fully ready to utilize for future fabrication and open-water testing. Moreover, the project began the certification process with a certification provider, allowing for a seamless continuation into future work beyond project-end.

16 TIDAL AND WAVE POWER↗
DOE OSTI2014

A Look Inside SLAC's Battery Lab

In this video, Stanford materials science and engineering graduate student Zhi Wei Seh shows how he prepares battery materials in SLAC's energy storage laboratory, assembles dime-sized prototype "coin cells" and then tests them to see how many charge-discharge cycles they can endure without losing their ability to hold a charge. Results to date have already set records: After 1,000 cycles, they retain 70 percent of their original charge.

25 ENERGY STORAGE↗
DOE OSTI2018

The International Science and Technology Center: Product of the Past or Prototype for the Future?

The International Science and Technology Center (ISTC) – originally formed in the early 1990s to address the potential issue of “brain drain” from underemployed and underpaid nuclear weapons scientists, engineers, and technicians in the former Soviet Union – still exists to this day. Through more than two decades of changing circumstances and worldviews, the ISTC has had to reorganize, move countries, streamline its internal processes, and broaden its scope of work in an attempt to remain a relevant and useful tool for international science cooperation in the 21st century. Critics see it as a product of the past in a modern world that no longer requires the redirection of former Soviet scientists, while proponents argue that the established networks and trust from the international community that the ISTC has developed throughout its history make it a critical and useful tool for current and future science cooperation and threat reduction. Through historical and budget analysis, this paper hopes to answer the following questions: (1) how has the ISTC evolved throughout its history to become what it considers to be a useful tool for the future of science cooperation and threat reduction, and (2) if the ISTC still serves a purpose, what is that purpose, and how can they continue to adapt and evolve to better serve that purpose?

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Hydrodynamic and Structural Response Modeling of a Prototype Floating Membrane Reservoir System for Pumped Storage Hydropower

Hydrodynamic, computational fluid dynamics, and finite-element modeling were performed for a novel floating membrane reservoir system design for closed-loop pumped storage hydropower application. The conceptual design, which is now protected under an invention disclosure with a patent pending, offers a potential low-cost, low-impact solution to address the high costs, long investment return periods, and environmental disruptions encountered with traditional pumped storage development while offering modularity to enable replication at many locations. Prior to physical tests on a prototype, this paper documents the response analysis and modeling completed to simulate hydraulic and structural performance under different reservoir deployment and alignment arrangements, evaluate system stability, and refine the conceptual design. The results indicate that the excitation frequency from vortex shedding is at least an order of magnitude lower than the water sloshing frequencies in the reservoir, the structural natural frequency of the entire reservoir, and the vibrational frequencies of the side membranes, although excitation frequencies from other sources could cause mechanical resonance under certain conditions. To control destabilizing effects and prevent rocking motion and vibration, the authors conclude that the design could be improved by including a support structure around the floating reservoir, which could also provide floating-membrane containment, improve safety, and facilitate vertical reservoir movement. These conclusions, based on hydrodynamic and structural response modeling, help define specifications for upcoming full-scale prototype construction, deployment, and testing. This study demonstrates standard modeling technique application to an innovative design for which similar applications have not been previously evaluated. As a result, the refined design is capable of improving the scalability and feasibility of pumped storage hydropower in the United States and will be considered for commercialization following prototype testing.

13 HYDRO ENERGY↗
DOE OSTI2016

Final Report: Rational Design of Wide Band Gap Buffer Layers for High-Efficiency Thin-Film Photovoltaics

The main objective of this project is to enable rational design of wide band gap buffer layer materials for CIGS thin-film PV by building understanding of the correlation of atomic-scale defects in the buffer layer and at the buffer/absorber interface with device electrical properties. Optimized wide band gap buffers are needed to reduce efficiency loss from parasitic absorption in the buffer. The approach uses first-principles materials simulations coupled with nanoscale analytical electron microscopy as well as device electrical characterization. Materials and devices are produced by an industrial partner in a manufacturing line to maximize relevance, with the goal of enabling R&D of new buffer layer compositions or deposition processes to push device efficiencies above 21%. Cadmium sulfide (CdS) is the reference material for analysis, as the prototypical high-performing buffer material.

14 SOLAR ENERGY↗
DOE OSTI2018

Hydraulic Drive of a Shipping Lock Gate with Automated Frequency-Throttle Control System

This project developed and built a hydraulic actuator prototype with an automated control system for moving the lifting and lowering gates of a shipping lock. In the course of the design engineering, a hydraulic actuator was experimentally developed. Trial operation of a hydraulic actuator was conducted on Lock No. 26 of the Balakovo RGSiS. This design of a hydraulic actuator is recommended to be used in upgrading and designing locks of hydraulic engineering constructions.

42 ENGINEERING↗
DOE OSTI2016

Physics Flash December 2016

This is the December 2016 issue of Physics Flash, the newsletter of the Physics Division of Los Alamos National Laboratory (LANL). In this issue, the following topics are covered: Novel liquid helium technique to aid highly sensitive search for a neutron electrical dipole moment; Silverleaf: Prototype Red Sage experiments performed at Q-site; John L. Kline named 2016 APS Fellow; Physics students in the news; First Entropy Engine quantum random number generator hits the market; and celebrating service.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗