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NASA NTRS2003

High-Frequency Testing of Composite Fan Vanes With Erosion-Resistant Coating Conducted

The mechanical integrity of hard, erosion-resistant coatings were tested using the Structural Dynamics Laboratory at the NASA Glenn Research Center. Under the guidance of Structural Mechanics and Dynamics Branch personnel, fixturing and test procedures were developed at Glenn to simulate engine vibratory conditions on coated polymer-matrix- composite bypass vanes using a slip table in the Structural Dynamics Laboratory. Results from the high-frequency mechanical bench testing, along with concurrent erosion testing of coupons and vanes, provided sufficient confidence to engine-endurance test similarly coated vane segments. The knowledge gained from this program will be applied to the development of oxidation- and erosion-resistant coatings for polymer matrix composite blades and vanes in future advanced turbine engines. Fan bypass vanes from the AE3007 (Rolls Royce America, Indianapolis, IN) gas turbine engine were coated by Engelhard (Windsor, CT) with compliant bond coatings and hard ceramic coatings. The coatings were developed collaboratively by Glenn and Allison Advanced Development Corporation (AADC)/Rolls Royce America through research sponsored by the High-Temperature Engine Materials Technology Project (HITEMP) and the Higher Operating Temperature Propulsion Components (HOTPC) project. High-cycle fatigue was performed through high-frequency vibratory testing on a shaker table. Vane resonant frequency modes were surveyed from 50 to 3000 Hz at input loads from 1g to 55g on both uncoated production vanes and vanes with the erosion-resistant coating. Vanes were instrumented with both lightweight accelerometers and strain gauges to establish resonance, mode shape, and strain amplitudes. Two high-frequency dwell conditions were chosen to excite two strain levels: one approaching the vane's maximum allowable design strain and another near the expected maximum strain during engine operation. Six specimens were tested per dwell condition. Pretest and posttest inspections were performed optically at up to 60 magnification and using a fluorescent-dye penetrant. Accumulation of 10 million cycles at a strain amplitude of two to three times that expected in the engine (approximately 670 Hz and 20g) led to the development of multiple cracks in the coating that were only detectable using fluorescent-dye penetrant inspection. Cracks were prevalent on the trailing edge and on the convex side of the midsection. No cracking or spalling was evident using standard optical inspection at up to 60 magnification. Further inspection may reveal whether these fine cracks penetrated the coating or were strictly on the surface. The dwell condition that simulated actual engine conditions produced no obvious surface flaws even after up to 80 million cycles had been accumulated at strain amplitudes produced at approximately 1500 Hz and 45g.

Bowman, Cheryl L.↗

DOE OSTI2024

A Cast of Thousands: How the IDEAS Productivity Project Has Advanced Software Productivity and Sustainability

Computational and data-enabled science and engineering are revolutionizing advances throughout science and society, at all scales of computing. For example, teams in the U.S. Department of Energy’s Exascale Computing Project have been tackling new frontiers in modeling, simulation, and analysis by exploiting unprecedented exascale computing capabilities—building an advanced software ecosystem that supports next-generation applications and addresses disruptive changes in computer architectures. However, concerns are growing about the productivity of the developers of scientific software. Members of the Interoperable Design of Extreme-scale Application Software project serve as catalysts to address these challenges through fostering software communities, incubating and curating methodologies and resources, and disseminating knowledge to advance developer productivity and software sustainability. This article discusses how these synergistic activities are advancing scientific discovery—mitigating technical risks by building a firmer foundation for reproducible, sustainable science at all scales of computing, from laptops to clusters to exascale and beyond.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Chemical Functional Groups Regulate Ion Concentrations and pHs in Nanopores

Understanding ion behaviors in functionalized nanopores is essential to deciphering reactions in both natural and engineered systems, such as sediments, biological ion channels, and membranes. While many efforts have shown the modified ion behaviors in the functionalized nanopores, a direct measurement and analysis to show how chemical functional groups affect ion concentrations in nanopores are critically needed. In this work, we present a plasmonic nanosensor that can measure the local concentrations of protons, anions (phosphate, nitrate, sulfate, and arsenate), and cations (mercury, lead, and copper) in functionalized nanopores, and we compare their concentrations in nanopores with the corresponding bulk concentrations. Notably, chemical functional groups induced ion concentrations differently in nanopores. In pristine nanopores and methyl- and phenyl-functionalized nanopores, we discovered an unexpected concurrence of an enhanced anion concentration and a suppressed cation concentration. In addition, the nanopore pH is dependent on bulk solution compositions and can be lower by 2.5 units, even when the bulk solution is well-buffered. In contrast, for hydrophilic (amine, thiol, and carboxyl) nanopores, pH depended on the p K a of the functional groups, and the heavy metal concentrations depended on chemical interactions with the functional groups. Our findings provide a better understanding of water chemistry in nanopores and can help precisely control ions in nanopores to benefit the design of membrane-based desalination techniques, CO 2 storage, and porous catalysts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

ENGINEERING,WIND ENERGY↗

NASA NTRS2019

Design of an Advanced Inlet Liner for the Quiet Technology Demonstrator 3

The utilization of advanced fan designs (including higher bypass ratios) and shorter engine nacelles has highlighted a need for increased fan noise reduction over a broad frequency range. Thus, improved broadband liner designs must account for these constraints and take advantage of novel liner configurations. With these observations in mind, the development and assessment of a broadband acoustic liner optimization process has been pursued through a series of design and experimental studies. In this work, an advanced inlet liner was designed for a Boeing 737MAX-7 to reduce drag and to improve the broadband noise reduction relative to conventional liners in use today. Specifically, a three layer liner was designed, fabricated, and flight tested as part of the Quiet Technology Demonstrator 3 flight test program. Initial tonal predictions captured the behavior of the measured data very well and both prediction and measurements show an increased acoustic benefit at larger observer angles, particularly at the takeoff condition. Ultimately, flight test results showed the three degree-of-freedom liner to provide a 3.2 EPNdB cumulative inlet component benefit and a 0.7 EPNdB cumulative airplane benefit over the production liner. This excellent result provides valuable validation of the broadband liner design process, as well as the enhancements made to the overall approach. It also illustrates the value of the design process in concurrently evaluating various liner designs (i.e., SDOF, MDOF, etc.) and their application to various locations. Thus, the design process may be applied with further confidence to investigate novel liner configurations in future design studies.

Nark, Douglas M.↗

NASA NTRS1999

Multidisciplinary Design Technology Development: A Comparative Investigation of Integrated Aerospace Vehicle Design Tools

This research effort is a joint program between the Departments of Aerospace and Mechanical Engineering and the Computer Science and Engineering Department at the University of Notre Dame. The purpose of the project was to develop a framework and systematic methodology to facilitate the application of Multidisciplinary Design Optimization (MDO) to a diverse class of system design problems. For all practical aerospace systems, the design of a systems is a complex sequence of events which integrates the activities of a variety of discipline "experts" and their associated "tools". The development, archiving and exchange of information between these individual experts is central to the design task and it is this information which provides the basis for these experts to make coordinated design decisions (i.e., compromises and trade-offs) - resulting in the final product design. Grant efforts focused on developing and evaluating frameworks for effective design coordination within a MDO environment. Central to these research efforts was the concept that the individual discipline "expert", using the most appropriate "tools" available and the most complete description of the system should be empowered to have the greatest impact on the design decisions and final design. This means that the overall process must be highly interactive and efficiently conducted if the resulting design is to be developed in a manner consistent with cost and time requirements. The methods developed as part of this research effort include; extensions to a sensitivity based Concurrent Subspace Optimization (CSSO) NMO algorithm; the development of a neural network response surface based CSSO-MDO algorithm; and the integration of distributed computing and process scheduling into the MDO environment. This report overviews research efforts in each of these focus. A complete bibliography of research produced with support of this grant is attached.

Renaud, John E.↗

NASA NTRS1998

Residual Stresses Modeled in Thermal Barrier Coatings

Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We examined the effect on stress during burner rig thermal cycling of the following independent variables: creep in the bond coat and top coat, oxidation, bond coat coefficient of thermal expansion, number of thermal cycles, and interfacial roughness. All these factors were suspected of influencing TBC failure. The model showed that all the material properties studied had a significant effect on the coating's residual stresses if the interface of the bond coat was rough. Bond coat expansion, bond coat oxidation, and bond coat creep had the highest effect on coating stresses, and these were highly interactive. The model also showed that the mechanism of stress generation during thermal cycling changed with the number of thermal cycles. Bond coat and top coat creep dominated stress generation during early thermal cycles, greatly increasing delamination stresses at the peaks of the bond coat. Therefore, creep is the prime driver for delamination cracking early in life, but cracking is limited to the bond coat peak region. Oxidation of the bond coat, on the other hand, tended to dominate stress generation during later cycles by greatly increasing delamination stresses over bond coat valleys. These results indicate that oxidation is the driver for the continued cracking necessary to cause ceramic layer spallation.

Freborg, A. M.↗

DOE OSTI2021

Hydropower Biological Evaluation Toolset Best Practice Guide

Field studies using live fish are necessary for the evaluation of turbine biological performance, but they cannot determine the specific hydraulic conditions or physical stresses experienced by the fish, the locations where deleterious conditions occur, or the specific causes of the biological response. Using the Sensor Fish (SF) sensing technology, this deficiency can be overcome because the SF can be released independently or concurrently with live fish directly into operating infrastructure, and it takes high-frequency measurements of hydraulic conditions such as pressure, acceleration, and rotation acting on a body in situ during downstream passage. The Hydropower Biological Evaluation Tools (HBET; Hou et al. 2018) software package, developed by Pacific Northwest National Laboratory (PNNL), is designed to assemble, organize, and process data collected by the PNNL-developed SF and by live fish. HBET was developed specifically to design SF field studies, process the raw data, and analyze the processed data efficiently and scientifically. Its objectives are to facilitate SF studies focused on characterizing hydraulic conditions and to apply SF data for evaluating the impacts on fish from passage through hydro-structures. HBET allows users to design new studies, analyze data, perform statistical analyses, and evaluate predicted biological responses. It can be used by researchers, turbine designers, hydropower operators, and regulators to evaluate hydro-structures to enhance environmental sustainability in a cost-effective manner.

13 HYDRO ENERGY↗

NASA NTRSDate not supplied

Human Capabilities Assessments for Autonomous Missions: A Multi-Team Research Effort to Reduce Risk in the Human-System Integration Architecture for Future Deep-Space Missions

In future exploration missions beyond low earth-orbit, crew will have to execute complex operations and respond to off-nominal events, without real-time support from Mission Control. It is anticipated that increased reliance on automated systems, including human-centric vehicle and information architecture, will need to be designed to support the crew; increased risk to performance, health, and safety may occur if these are not implemented appropriately. The Human Factors and Behavioral Performance Element (HFBP) in the NASA Human Research Program supports research to characterize and mitigate such human health and performance risks, including the Risk of Adverse Outcome Due to Inadequate Human Systems Integration Architecture (HSIA). The HSIA risk addresses the integration of onboard capability and the crew roles and responsibilities necessary to enable the crew to respond effectively and efficiently in the increasingly autonomous mission operations environment. In 2017, HFBP released the “Human Capabilities Assessments for Autonomous Missions” (HCAAM) research topic to address HSIA related questions. HCAAM is a major NASA research effort that has assembled a multidisciplinary team from seven institutions to work closely with design and engineering efforts on research towards developing and refining human performance standards, guidelines and automation tools. The scientific focus is on quantitative assessment of human capabilities relevant to future deep-space missions during which earth/spacecraft communication is so delayed and intermittent that the crew must be able to function autonomously. The integrated strategy of the HCAAM project characterizes human capabilities and limitations related to potential performance decrements during long duration exploration mission spaceflight as relevant to both routine and complex task performance; defines system characteristics that reduce the likelihood or impact of potential decrements in human performance capabilities; performs integrated assessment of intelligent system responses within the context of an operational environment with relevant NASA tools, systems, and data structures in order to determine positive or negative interactions and validate recommended approaches; and proposes specific updates to existing standards and guidelines for inclusion in NASA handbooks for the design of future spacecraft intelligent systems that provide crew performance assessment/feedback, and to also serve as decision-support aids for the onboard crew (i.e., NASA-STD-3001, and NASA/SP-Human Integration Design Handbook (HIDH)). The scientific research vectors being addressed by the seven HCAAM teams include: - crew task performance (accuracy, efficiency) (crew + automation) - crew performance (accuracy, efficiency) - crew Situation Awareness - procedure design and multi-modal enhancement - concurrent tasking (mixed manual + some level of autonomy) - task handover - crew self-planning and time-lining - task design - trust in automation, real-time calibration - human multi-sensory feedback and guidance - human trust in on-board software-based intelligent assistants - virtual assistants The presentation will highlight plans and progress made in each of these research areas as well as the methods by which surrogate astronaut crews in the NASA JSC HERA spaceflight analog facility will function as human test subjects for all of the HCAAM research projects.

HCAAM VNSCOR↗

DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗

NASA NTRS2018

Overview of the Exploration Exercise Device Validation Study Plans

The NASA has determined that a multi-functional exercise device will be developed for use as an exercise device during exploration missions. The device will allow for full body resistance and metabolic exercise necessary to minimize physiological losses during space flight and to maintain fitness necessary to perform critical mission tasks. Prior to implementation as an exercise device on an Exploration vehicle, there will be verification and validation testing completed to determine device efficacy at providing the necessary training stimuli to achieve desired goals. Because the exploration device will be new device that has yet be specified, specific Verification and Validation (V&V) protocols have yet to be developed. Upon delivery of an exploration exercise device training unit, stakeholders throughout NASA will develop V&V plans that include ground-based testing and testing on the International Space Station (ISS). Stakeholders will develop test protocols that include success criterion for the device. Ground tests will occur at NASA Johnson Space Station prior to flight testing. The intents of the ground tests are to allow crew, spaceflight medicine, science, engineering, Astronaut Strength, Conditioning, and Reconditioning staff, and others to gain experience in the best utilization of the device. The goal is to obtain an evidence base for recommending use of the device on the ISS. The developed protocol will be created to achieve multiple objectives, including determining if the device provides an adequate training stimulus for 5th - 95th percentile males and females, allows for exercise modalities that protect functional capability, and is robust and can withstand extensive human use. Although protocols are yet to be determined, current expectations include use of the device by test subjects and current crew in order to obtain quantitative and qualitative feedback. Information obtained during the ground tests may be used to influence device modifications during design iterations. Assuming successful ground tests, the device will be installed on the ISS for testing during space flight. Spaceflight testing is envisioned to include an activation and checkout (ACO) phase and a V&V phase. During the ACO phase, 1-2 crewmembers will exercise with the device to ensure proper function. ACO is expected to last multiple months because of the many modes and methods of exercise that need to be assessed. However, the goal is to complete the ACO as quickly as possible. Once successful ACO occurs, the crew will be free to use the device for normal exercise pending concurrence from stakeholders. V&V tests on the ISS will ideally consist of crew using the device for all of their exercise for an entire mission. Exercise prescriptions will be supplied that replicate expected prescriptions during exploration missions. Crew that are not enrolled in the V&V studies would be also free to use the device as their schedule permits. As experience is gained by users, exercise protocols could change. The intent of all V&V testing is to ensure that all have thorough understanding of experience at optimizing device capability

DeWitt, J. K.↗

NASA NTRS1994

Constraint based scheduling for the Goddard Space Flight Center distributed Active Archive Center's data archive and distribution system

The Goddard Space Flight Center (GSFC) Distributed Active Archive Center (DAAC) has been operational since October 1, 1993. Its mission is to support the Earth Observing System (EOS) by providing rapid access to EOS data and analysis products, and to test Earth Observing System Data and Information System (EOSDIS) design concepts. One of the challenges is to ensure quick and easy retrieval of any data archived within the DAAC's Data Archive and Distributed System (DADS). Over the 15-year life of EOS project, an estimated several Petabytes (10(exp 15)) of data will be permanently stored. Accessing that amount of information is a formidable task that will require innovative approaches. As a precursor of the full EOS system, the GSFC DAAC with a few Terabits of storage, has implemented a prototype of a constraint-based task and resource scheduler to improve the performance of the DADS. This Honeywell Task and Resource Scheduler (HTRS), developed by Honeywell Technology Center in cooperation the Information Science and Technology Branch/935, the Code X Operations Technology Program, and the GSFC DAAC, makes better use of limited resources, prevents backlog of data, provides information about resources bottlenecks and performance characteristics. The prototype which is developed concurrently with the GSFC Version 0 (V0) DADS, models DADS activities such as ingestion and distribution with priority, precedence, resource requirements (disk and network bandwidth) and temporal constraints. HTRS supports schedule updates, insertions, and retrieval of task information via an Application Program Interface (API). The prototype has demonstrated with a few examples, the substantial advantages of using HTRS over scheduling algorithms such as a First In First Out (FIFO) queue. The kernel scheduling engine for HTRS, called Kronos, has been successfully applied to several other domains such as space shuttle mission scheduling, demand flow manufacturing, and avionics communications scheduling.

Short, Nick, Jr.↗

NASA NTRS1998

Multidisciplinary Design Technology Development: A Comparative Investigation of Integrated Aerospace Vehicle Design Tools

This research effort is a joint program between the Departments of Aerospace and Mechanical Engineering and the Computer Science and Engineering Department at the University of Notre Dame. Three Principal Investigators; Drs. Renaud, Brockman and Batill directed this effort. During the four and a half year grant period, six Aerospace and Mechanical Engineering Ph.D. students and one Masters student received full or partial support, while four Computer Science and Engineering Ph.D. students and one Masters student were supported. During each of the summers up to four undergraduate students were involved in related research activities. The purpose of the project was to develop a framework and systematic methodology to facilitate the application of Multidisciplinary Design Optimization (N4DO) to a diverse class of system design problems. For all practical aerospace systems, the design of a systems is a complex sequence of events which integrates the activities of a variety of discipline "experts" and their associated "tools". The development, archiving and exchange of information between these individual experts is central to the design task and it is this information which provides the basis for these experts to make coordinated design decisions (i.e., compromises and trade-offs) - resulting in the final product design. Grant efforts focused on developing and evaluating frameworks for effective design coordination within a MDO environment. Central to these research efforts was the concept that the individual discipline "expert", using the most appropriate "tools" available and the most complete description of the system should be empowered to have the greatest impact on the design decisions and final design. This means that the overall process must be highly interactive and efficiently conducted if the resulting design is to be developed in a manner consistent with cost and time requirements. The methods developed as part of this research effort include; extensions to a sensitivity based Concurrent Subspace Optimization (CSSO) MDO algorithm; the development of a neural network response surface based CSSO-MDO algorithm; and the integration of distributed computing and process scheduling into the MDO environment. This report overviews research efforts in each of these focus. A complete bibliography of research produced with support of this grant is attached.

Renaud, John E.↗

DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗

DOE OSTI2022

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗

DOE OSTI2020

Experimentally Validated Computational Modeling of Creep and Creep-Cracking for Nuclear Concrete Structures

In a Nuclear Power Plant, one of the most important components is the concrete nuclear reactor cavity, which serves both a structural and protective function as the biological radiation shield. Given that creep has been identified as a major knowledge gap in the assessment of nuclear structures (NUREG/CR-7153), this work helps to further the understanding of creep behavior of massive concrete containment structures for decades to enable safe and long-term operation of these facilities. This project has developed a robust, experimentally validated model to predict creep in nuclear concrete structures for up 60 years using short-term creep data thereby enabling a longer service life of critical facilities and early detection of structural failure. The work presented in this report is a pairing of computational and experimental methods. For the first time, the time temperature superposition (TTS) principle was successfully used to generate a uniaxial creep compliance master curve to predict mortar creep response for up to 22,500 days (nearly 60 years) at a reference temperature of 20°C. These data were used as input into finite element analysis (FEA) codes that use highly realistic random, 3D concrete microstructures from reconstructed coarse limestone aggregates. Finite element analysis performed provides the ability to quickly upscale mortar viscoelastic behavior to long-term concrete creep/relaxation data. A master creep compliance curve, constructed from the TTS principle, spanning 27 years, was used to validate two and a half decades of simulated concrete creep. Concurrently, three different simulated wall specimens were designed to mimic the behavior of post-tensioned concrete nuclear containment facility vessel walls over time as a result of concrete creep. The specimens were designed with different thicknesses, transverse and longitudinal reinforcement ratios, and level of post-tensioning stress. Each specimen contained various instrumentation to measure internal concrete temperature, concrete strain, and post-tensioning strain hourly for over 3 years. The concrete creep model developed in this project, based on the FEA concrete simulations, was applied to simulate the structural-scale experiments of prestressed concrete walls conducted in this project using the Grizzly code. These models can represent the effects of reinforcing and prestressing. Although there are some discrepancies with the experimental data, the model can predict the overall trends of the creep response in these experiments. One of these experimental models was also applied to an extended time to demonstrate how the findings from this study can be used to predict the behavior of actual structures of interest that have been in service for extended periods of time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2011

Licklider Transmission Protocol Implementation

This software is an implementation of the Licklider Transmission Protocol (LTP), a communications protocol intended to support the Bundle Protocol in Delay-Tolerant Network (DTN) operations. LTP is designed to provide retransmission-based reliability over links characterized by extremely long message round-trip times and/or frequent interruptions in connectivity. Communication in interplanetary space is the most prominent example of this sort of environment, and LTP is principally aimed at supporting long-haul reliable transmission over deep-space RF links. Like any reliable transport service employing ARQ (Automatic Repeat re-Quests), LTP is stateful. In order to assure the reception of a block of data it has sent, LTP must retain for possible retransmission all portions of that block which might not have been received yet. In order to do so, it must keep track of which portions of the block are known to have been received so far, and which are not, together with any additional information needed for purposes of retransmitting part, or all, of the block. Long round-trip times mean substantial delay between the transmission of a block of data and the reception of an acknowledgement from the block s destination, signaling arrival of the block. If LTP postponed transmission of additional blocks of data until it received acknowledgement of the arrival of all prior blocks, valuable opportunities to use what little deep space transmission bandwidth is available would be forever lost. For this reason, LTP is based in part on a notion of massive state retention. Any number of requested transmission conversations (sessions) may be concurrently in flight at various displacements along the link between two LTP engines, and the LTP engines must necessarily retain transmission status and retransmission resources for all of them. Moreover, if any of the data of a given block are lost en route, it will be necessary to retain the state of that transmission during an additional round trip while the lost data are retransmitted; even multiple retransmission cycles may be necessary. LTP's possible multiplicity of sessions per association makes it necessary for each segment of application data to include an additional demultiplexing token: a session ID that uniquely identifies the session in which the segment was issued and, implicitly, the block of data being conveyed by this session. This software comprises a prototype implementation developed by Johns Hopkins University APL in cooperation with JPL, together with adaptations that improve the robustness, correctness, and operability of that implementation.

Burleigh, Scott C.↗

DOE OSTI2023

Scale-up and techno-economic analysis of microbial electrolysis cells for hydrogen production from wastewater

Microbial electrolysis cells (MECs) have demonstrated high-rate H 2 production while concurrently treating wastewater, but the transition in scale from laboratory research to systems that can be practically applied has encountered challenges. It has been more than a decade since the first pilot-scale MEC was reported, and in recent years, many attempts have been made to overcome the barriers and move the technology to the market. This study provided a detailed analysis of MEC scale-up efforts and summarized the key factors that should be considered to further develop the technology. We compared the major scale-up configurations and systematically evaluated their performance from both technical and economic perspectives. We characterized how system scale-up impacts the key performance metrics such as volumetric current density and H 2 production rate, and we proposed methods to evaluate and optimize system design and fabrication. In addition, preliminary techno-economic analysis indicates that MECs can be profitable in many different market scenarios with or without subsidies. Here, we also provide perspectives on future development needed to transition MEC technology to the marketplace.

42 ENGINEERING↗