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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Nonlinear Characterization of a Joint Exhibiting a Reduction in Damping at High Energy

Even with the advent of additive manufacturing, the vast majority of complex structures are comprised of individual components held together with bolted joints. However, bolted joints present a challenge for mechanical design as they are a source of nonlinearity and increase the uncertainty in the overall behavior of the system in a dynamic environment. While many advances have been made in the ability to accurately model and test bolted joints, it is still an open area of research. Modes of vibration that exercise bolted joints typically exhibit nonlinear behavior where, with increased excitation level, the natural frequency decreases (i.e. softens) and the damping increases. However, the system under study for this work has an axial mode which does not follow this trend; it does soften as expected, but, after an initial increase, the apparent damping decreases with excitation amplitude. At the highest excitation level, the frequency of the mode decreases to that of a nearby bending mode and the response is amplified nearly 500% above that at lower levels. It is unclear whether the decrease in damping is due to the coupling of the two modes or if it is a characteristic of the axial mode. Therefore, the objective of this project is to investigate the coupling between the axial and bending modes and the dynamics leading to the decrease in damping.

42 ENGINEERING↗
DOE OSTI2021

Biomechanical Comparison of Anatomic Restoration of the Ulnar Footprint vs Traditional Ulnar Tunnels in Ulnar Collateral Ligament Reconstruction

Background: Current techniques for ulnar collateral ligament (UCL) reconstruction do not reproduce the anatomic ulnar footprint of the UCL. The purpose of this study was to describe a novel UCL reconstruction technique that utilizes proximal-to-distal ulnar bone tunnels to better re-create the anatomy of the UCL and to compare the biomechanical profile at time zero among this technique, the native UCL, and the traditional docking technique. Hypothesis: The biomechanical profile of the anatomic technique is similar to the native UCL and traditional docking technique. Study Design: Controlled laboratory study. Methods: Ten matched cadaveric elbows were potted with the forearm in neutral rotation. The palmaris longus tendon graft was harvested, and bones were sectioned 14 cm proximal and distal to the elbow joint. Specimen testing included (1) native UCL testing performed at 90° of flexion with 0.5 N·m of valgus moment preload, (2) cyclic loading from 0.5 to 5 N·m of valgus moment for 1000 cycles at 1 Hz, and (3) load to failure at 0.2 mm/s. Elbows then underwent UCL reconstruction with 1 elbow of each pair receiving the classic docking technique using either anatomic (proximal to distal) or traditional (anterior to posterior) tunnel locations. Specimen testing was then repeated as described. Results: There were no differences in maximum load at failure between the anatomic and traditional tunnel location techniques (mean ± SD, 34.90 ± 10.65 vs 37.28 ± 14.26 N·m; P = .644) or when including the native UCL (45.83 ± 17.03 N·m; P = .099). Additionally, there were no differences in valgus angle after 1000 cycles across the anatomic technique (4.58°± 1.47°), traditional technique (4.08°± 1.28°), and native UCL (4.07°± 1.99°). The anatomic group and the native UCL had similar valgus angles at failure (24.13°± 5.86° vs 20.13°± 5.70°; P = .083), while the traditional group had a higher valgus angle at failure when compared with the native UCL (24.88°± 6.18° vs 19.44°± 5.86°; P = .015). Conclusion: In this cadaveric model, UCL reconstruction with the docking technique utilizing proximal-to-distal ulnar tunnels better restored the ulnar footprint while providing valgus stability comparable with reconstruction with the docking technique using traditional anterior-to-posterior ulnar tunnel locations. These results suggest that utilization of the anatomic tunnel location in UCL reconstruction has similar biomechanical properties to the traditional method at the time of initial fixation (ie, not accounting for healing after reconstruction in vivo) while keeping the ulnar tunnels farther from the ulnar nerve. Further studies are warranted to determine if an anatomically based UCL reconstruction results in differing outcomes than traditional reconstruction techniques. Clinical Relevance: Current UCL reconstruction techniques do not accurately re-create the ulnar UCL footprint. The UCL is a dynamic constraint to valgus loads at the elbow, and a more anatomic reconstruction may afford more natural joint kinematics. This more anatomic technique performs similarly to the traditional docking technique at time zero, and the results of this study may offer a starting point for future in vivo studies.

Chang, Edward S.↗
DOE OSTI2021

Reconstructing the Universe: Testing the Mutual Consistency of the Pantheon and SDSS/eBOSS BAO Data Sets with Gaussian Processes

We test the mutual consistency between the baryon acoustic oscillation measurements from the eBOSS SDSS final release and the Pantheon supernova compilation in a model-independent fashion using Gaussian process regression. We also test their joint consistency with the ΛCDM model in a model-independent fashion. We also use Gaussian process regression to reconstruct the expansion history that is preferred by these two data sets. While this methodology finds no significant preference for model flexibility beyond ΛCDM, we are able to generate a number of reconstructed expansion histories that fit the data better than the best-fit ΛCDM model. These example expansion histories may point the way toward modifications to ΛCDM. We also constrain the parameters Ω{sub k} and H {sub 0} r {sub d} both with ΛCDM and with Gaussian process regression. We find that H {sub 0} r {sub d} = 10,030 ± 130 km s{sup −1} and Ω{sub k} = 0.05 ± 0.10 for ΛCDM and that H {sub 0} r {sub d} = 10,040 ± 140 km s{sup −1} and Ω{sub k} = 0.02 ± 0.20 for the Gaussian process case.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling the production of parts larger than the mold dimensions. Composite panels made of 20 wt% short carbon fiber reinforced acrylonitrile butadiene styrene (CF/ABS) were joined using MI features of various geometries, namely tree (TR), dovetail (Dov), rectangle 2 (Rect2), and rectangle 1 (Rect1), and their in-plane strength was evaluated. The resultant strength of the tested MI joints reached up to 74 % of the baseline tensile strength (i.e., the ‘no joint’ case). Observations from optical and scanning electron microscopy revealed inadequate polymer diffusion between the adherends, indicating that the joint strength was primarily derived from mechanical interlocking. Additionally, the fracture surfaces exhibited stress-whitening marks, which were characterized using differential scanning calorimetry (DSC). The increase in melting enthalpy suggested local stretching of polymer chains due to MI. Finite element analysis (FEA) indicated that the Rect1 MI feature, which generated the lowest stress concentration, outperformed the others in terms of joint strength, achieving 42 MPa. As a demonstration of the MI joining method, a battery box tray measuring 108 cm × 34 cm using a mold with an effective dimension of 36 cm × 34 cm successfully manufactured, resulting in a part with an area three times larger than the mold. In conclusion, this study presents a promising approach to improving composite joining techniques while minimizing production complexities.

In-plane joining↗
DOE OSTI2025

Polyhalohydrins: Investigating Vicinal Functionalities by Ring-Opening of Epoxides on Polyolefins

Halohydrins are functional groups that are underexplored in polymer science. This study synthesized and examined structure–property relationships of halohydrin-functionalized polymers derived from polycyclooctene (PCOE), which was obtained via ring-opening metathesis polymerization (ROMP). The polyhalohydrins, including polychlorohydrin, polybromohydrin, and polyiodohydrin, were produced through a two-step process involving epoxidation of PCOE followed by epoxide ring-opening using hydrochloric, hydrobromic, or hydroiodic acid. These stereoirregular and regioirregular polymers are amorphous as measured by differential scanning calorimetry and X-ray scattering. Lap joint shear testing revealed an enhanced adhesive performance in polychlorohydrin and polybromohydrin, with the former demonstrating nearly three times the ultimate shear stress compared to a model polyethylene, hydrogenated PCOE. Additionally, contact angle measurements and surface free energy analysis showed an increase in hydrophilicity and polarity from iodine- to bromine- to chlorine-functionalized polyhalohydrins, aligning with trends in adhesion strength. Furthermore, these results underscore the potential of halohydrin functionalization as a versatile approach for tuning surface properties, offering new opportunities for polymer-to-polymer transformations.

Functional groups↗
DOE OSTI2022

Signatures of Light Massive Relics on non-linear structure formation

ABSTRACT Cosmologies with Light Massive Relics (LiMRs) as a subdominant component of the dark sector are well-motivated from a particle physics perspective, and can also have implications for the σ8 tension between early and late time probes of clustering. The effects of LiMRs on the cosmic microwave background (CMB) and structure formation on large (linear) scales have been investigated extensively. In this paper, we initiate a systematic study of the effects of LiMRs on smaller, non-linear scales using cosmological N-body simulations; focusing on quantities relevant for photometric galaxy surveys. For most of our study, we use a particular model of non-thermal LiMRs but the methods developed generalizing to a large class of LiMR models – we explicitly demonstrate this by considering the Dodelson–Widrow velocity distribution. We find that, in general, the effects of LiMR on small scales are distinct from those of a ΛCDM universe, even when the value of σ8 is matched between the models. We show that weak lensing measurements around massive clusters, between ∼0.1 h−1Mpc and ∼10 h−1Mpc, should have sufficient signal-to-noise in future surveys to distinguish between ΛCDM and LiMR models that are tuned to fit both CMB data and linear scale clustering data at late times. Furthermore, we find that different LiMR cosmologies indistinguishable by conventional linear probes can be distinguished by non-linear probes if their velocity distributions are sufficiently different. LiMR models can, therefore, be best tested by jointly analyzing the CMB and late-time structure formation on both large and small scales.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

A Short-Term Solar Forecasting Platform Using a Physics-Based Smart Persistence Model and Data Imputation Method

Electrical energy plays vital role in our socio-economic activity and therefore ensuring the reliability of the electric grid, from the generation, transmission and distribution level is critical. In order to maintain the power system parameter viz., frequency, voltage, etc., optimally, balancing of generation and consumption is very much essential. However, solar energy is infirm power by nature this is due to cloud cover / other local phenomena. Hence, Photovoltaic (PV) power generation brings a significant challenge to the grid operator due to the variability of the solar energy. The complexity of this challenge in terms of planning and dispatch ability of PV resources, aggravates with the high penetration of solar energy into the electric grid. In this setting, reliable solar radiation forecasting models based on accurate and quality input data become essential. In order to develop a suitable model for predicting solar radiation, quality historical / real time measurement is also needed. Under this study NIWE and NREL jointly developed / tested short-term solar forecasting frameworks using a smart persistence and physics-based smart persistence models for intra-hour forecasting of solar radiation (PSPI) and benchmarked 9 different data imputation techniques in 15 Solar Radiation Resource Assessment (SRRA) stations, located at different parts of India. During any measurement campaign, due to various technical reasons, we may miss few observations. However, the missing observation often reduce the performance of any forecasting model. Therefore, suitable data imputation method would assist us to obtain continuous observation of solar radiation. A station-by-station and method-by-method analysis was carried out to understand the performance of each model. Based on our analysis, among all the data imputation methods, the Kalman data imputation method is better for Indian Weather condition. In addition, Kalman StructTS, Linear, Stine and Arima methods yield slightly inferior accuracy compared to Kalman, but outperform the other methods. The extended solar radiation data are used by solar forecasting models to provide the prediction of solar radiation at 15 SRRA stations. As far as short term forecasting model is concerned, the PSPI model outperforms the Smart Persistence model. However, the forecast error is increases with the forecasting horizon.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Corrosion Control in Carbon Fiber Reinforced Plastic (CFRP) Composite-Aluminum Closure Panel Hem Joints

This project targeted the implementation of CFRP/Al closure panels as a drop-in replacement for all-aluminum closures used in automobile production today. The project focused on the development of corrosion fundamentals involving CFRP materials and the use of those materials in mixed-material joints. Numerous studies were completed to benchmark current materials and test mixed metal joints. Good correlation was found between outdoor exposures and laboratory cyclic corrosion testing. The insights from the corrosion testing fundamentals and benchmarking phases informed the development of low-cure adhesive and electrocoats and conductive primers for the CFRP. Adhesive and electrocoat materials were successfully developed meeting low-cure targets for bake (150C/10min). These materials were scaled-up and used to produce 5 prototype liftgates to further evaluate CFRP/Al joints in a full-scale part. The lower cure materials enabled mitigation of CTE mismatch and reduced the required bake temperature, resulting in reduced part distortion. Corrosion testing of the liftgates revealed unexpected increases in corrosion relative to the standard bake materials. While rigorous evaluation of the parts was not possible due to numerous complexities associated with prototype testing, the results provided significant insights into the material behavior of CFRP/Al joints. Key learnings from the project included a better understanding of the system complexity (interplay of substrate/primer conductivity, production of full-scale prototypes), advances in coating/adhesive design for low-cure applications involving CFRP, and advancement of corrosion test protocols for CFRP.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Joint Work Plan for DPC Filler Testing

The US generates approximately 2,000 Metric Tons of Heavy Metal (MTHM) of commercial spent fuel (SNF) each year and currently stores ~ 85,000 MTHM of commercial SNF at 70+ reactor sites, the disposal of which is the responsibility of the US Department of Energy (DOE). SNF is initially stored in spent nuclear fueld pools (SFPs). SFPs were initially constructed by US utilities for temporary fuel storage, but with no final disposal pathway available, SFPs are reaching capacity. To allow continued operation of the nation's commercial nuclear reactor fleet, utilities started transferring SNF from SFPs (wet storage) to dry cask storage systems, typically using dual-purpose (storage and transportation) canisters (DPCs). And while DPCs were designed, licensed and loaded to meet Nuclear Regulatory Commission (NRC) requirements that preclude the possibility of a critical event during SNF storage and transport, they were not designed or loaded to preclude the possibility of a criticality event during the regulated post-closure period following disposal, which could be up to 1,000,000 years (Price, 2019). DPC filler option criteria are detailed and materials that exhibit these attributes are explored. This document is an update of the SNL Joint Workplan on Filler Investigations for DPCs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles

The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Gearbox Reliability Collaborative 1.5 (GRC1.5) Project: Joint Industry Megawatt Scale Gearbox Field Tests: Cooperative Research and Development (Final Report) CRADA Number CRD-16-00608

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative 1.5 (GRC1.5) will undertake field testing on a commercial multi-megawatt wind turbine gearbox to collect loading data as installed in the turbine to thoroughly characterize gearbox loads and responses during actual in-field conditions. A chief outcome is to provide publicly available operational loading data to the industry. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox; thus, facilitating improvements in the gearbox components, lubrication system, power converter or turbine controller.

17 WIND ENERGY↗
DOE OSTI2021

Drivetrain Reliability Collaborative 1.5 (DRC1.5) Project: Joint Industry Megawatt Scale Gearbox Field Tests: Cooperative Research and Development (Final Report) CRADA Number CRD-17-00702

A new Department of Energy (DOE)/NREL industry collaboration called the Drivetrain Reliability Collaborative 1.5 (DRC1.5) will undertake field testing on a commercial multi-megawatt wind turbine drivetrain to collect loading data as installed in the turbine to thoroughly characterize drivetrain loads and responses during actual in-field conditions. A chief outcome is to provide publicly available operational loading data to the industry. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the drivetrain; thus, facilitating improvements in the drivetrain components, lubrication system, power converter or turbine controller.

17 WIND ENERGY↗
DOE OSTI2024

GRC1.5 Project: Joint Industry Megawatt Scale Gearbox Field Tests (Final Report)

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative (GRC) 1.5 will undertake field testing on current commercial multi-megawatt wind turbine gearboxes to collect loading data from installed turbines to thoroughly characterize gearbox input loads and responses during actual in-field conditions. A chief outcome is to provide operational loading data relative to the most common failure modes. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox, thus facilitating improvements in the gearbox, power converter or turbine controller.

17 WIND ENERGY↗
DOE OSTI2023

Performance of low-loss demountable joints between CORC ® cable-in-conduit-conductors at magnetic fields up to 8 T developed for fusion magnets

Abstract High-temperature superconductors (HTS) are promising candidates for use in the high-field magnets needed in particle accelerators and fusion reactors. HTS conductor on round core (CORC ® ) cables and wires wound from ReBa 2 Cu 3 O 7- x (REBCO) coated tapes are being developed for use in high-field magnet applications including fusion magnets operating at currents beyond 80 kA, requiring them to be bundled into cable-in-conduit conductor (CICC) configurations. The use of HTS cables enable demountable superconducting fusion magnets that would allow easier access to the fusion machine for maintenance and parts replacement. Such demountable magnets require practical, low-resistance joints, capable of injecting current uniformly into the many REBCO tapes that make up different cable designs. Optimization steps on CORC ® cables have resulted in high-current terminations and joints with a joint resistance measured between a pair of 30-tape CORC ® cables of 51 nΩ at 76 K and 1.9 nΩ at 4 K. Demountable joints between CICCs consisting of six CORC ® cables arranged in flat and round configurations were also tested and compared to joints between low-temperature superconducting (LTS) CICCs consisting of NbTi Rutherford cables. Samples were paired into two configurations (LTS-to-LTS and HTS-to-HTS) with a demountable joint between them that were each tested in series with currents up to 10 000 A in an applied background magnetic field of up to 8 T. The total loop resistance of the HTS-to-HTS sample, including their terminations and joint, was about 4 nΩ at 4 K in self-field with the resistance of the copper pressed joint being less than 1 nΩ. At 8 T, the total loop resistance increased to 6.9 nΩ with the pressed joint contributing 1.4 nΩ. These initial tests prove the feasibility of producing remountable (dry) joints with low resistance between superconducting magnet windings in future compact fusion machines.

Physics↗