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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
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DOE OSTI2021

Comprehensive Margin Assessment of the ASME Section III, Division 5, Class A Primary Load Design Rules

This report provides a comprehensive margin assessment of the ASME Section III, Division 5, Subsection HB, Subpart B rules for the design of high temperature reactor components against load controlled stress limits. These rules, often called the Code primary load design rules, provide protection against creep rupture and plastic collapse under steady conditions. The method adopted here is to compare the deterministic ASME design life, according to the primary load design rules, against the expected, statistical service life of the component, considering creep rupture as the relevant failure mode. The report provides the design margin of the ASME rules in terms of the probability of premature failure -- the probability that the component fails in service before reaching the ASME design life. To complete this assessment, the report describes the development of a statistical creep life assessment procedure accounting for variations in the component loading, material creep rate, and the material rupture time. This includes a novel method for correlating creep rupture data using a Gaussian process accounting for heat-to-heat variation in the Larson-Miller time-temperature parameter. The report applies the complete margin assessment process to quantify the design margin inherent in the ASME primary load design rules as a function of temperature for relevant component geometries and materials. The overall conclusion is that the ASME rules are conservative, providing designs with very small probability of premature failure, but some optimization of the Code design rules is possible to provide a more uniform design margin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Demonstration of the surveillance test article for an advanced reactor surveillance test program

Operational environments in generation IV reactors involve corrosive and irradiative conditions at elevated temperatures. Typical reactor operations consist of transients which impose cyclic loads on reactor components. These cyclic loads, combined with corrosive and irradiative environments, result in synergistic degradation of component materials. However, limited data exists on the coupled damage effects on materials for reactor environments. While the surrogate material surveillance concept has been used in light water reactors to assess irradiation damage, existing material surveillance technologies are not suitable for in-situ monitoring of coupled material degradation. The materials surveillance program focuses on material degradation management and the estimation of remaining life of reactor components through surveillance test articles. This paper presents the design and analysis methodology of a bi-metal surveillance test article, which uses difference in thermal expansion coefficient between two metals to induce in-situ cyclic loads. This report presents the work conducted in FY 25, to test the surveillance test article in air and salt environments. These test specimens were evaluated after thermal cycle exposure and remaining life is measured through creep test.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Modeling District Heating and Cooling Systems with URBANopt, GeoJSON to Modelica Translator, and the Modelica Buildings Library

The URBANopt project has successfully leveraged OpenStudio/EnergyPlus to model buildings and electrical systems at an urban scale; however, URBANopt has lacked the ability to model district thermal energy systems until recently. This paper will present the modeling infrastructure that was developed specifically for the analysis of district heating and cooling systems, and how it is integrated into the existing URBANopt framework. The paper also discusses the development of new models added to the Modelica Buildings Library to model various district energy system components including loads, energy transfer stations (ETS), distribution networks, and central plants. The paper describes how different building loads can be modeled including time series, TEASER reduced-order models, or Spawn of EnergyPlus models. URBANopt District Energy Systems allows the user to switch between the various configurations.

district heating and cooling↗
DOE OSTI2024

A core of cell wall proteins functions in wall integrity responses in Arabidopsis thaliana

Abstract Cell walls surround all plant cells, and their composition and structure are tightly regulated to maintain cellular and organismal homeostasis. In response to wall damage, the cell wall integrity (CWI) system is engaged to ameliorate effects on plant growth. Despite the central role CWI plays in plant development, our current understanding of how this system functions at the molecular level is limited. Here, we investigated the transcriptomes of etiolated seedlings of mutants of Arabidopsis thaliana with defects in three major wall polysaccharides, pectin ( quasimodo2 ), cellulose ( cellulose synthase3 je5 ), and xyloglucan ( xyloglucan xylosyltransferase1 and 2 ), to probe whether changes in the expression of cell wall‐related genes occur and are similar or different when specific wall components are reduced or missing. Many changes occurred in the transcriptomes of pectin‐ and cellulose‐deficient plants, but fewer changes occurred in the transcriptomes of xyloglucan‐deficient plants. We hypothesize that this might be because pectins interact with other wall components and/or integrity sensors, whereas cellulose forms a major load‐bearing component of the wall; defects in either appear to trigger the expression of structural proteins to maintain wall cohesion in the absence of a major polysaccharide. This core set of genes functioning in CWI in plants represents an attractive target for future genetic engineering of robust and resilient cell walls.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Using Machine Learning Tools to Predict Compressor Stall

Clean energy has become an increasingly important consideration in today’s power systems. As the push for clean energy continues, many coal-fired power plants are being decommissioned in favor of renewable power sources such as wind and solar. However, the intermittent nature of renewables means that dynamic load following traditional power systems is crucial to grid stability. With high flexibility and fast response at a wide range of operating conditions, gas turbine systems are poised to become the main load following component in the power grid. Yet, rapid changes in load can lead to fluid flow instabilities in gas turbine power systems. These instabilities often lead to compressor surge and stall, which are some of the most critical problems facing the safe and efficient operation of compressors in turbomachinery today. Although the topic of compressor surge and stall has been extensively researched, no methods for early prediction have been proven effective. This study explores the utilization of machine learning tools to predict compressor stall. The long short-term memory (LSTM) model, a form of recurrent neural network (RNN), was trained using real compressor stall datasets from a 100 kW recuperated gas turbine power system designed for hybrid configuration. Two variations of the LSTM model, classification and regression, were tested to determine optimal performance. The regression scheme was determined to be the most accurate approach, and a tool for predicting compressor stall was developed using this configuration. Overall, results show that the tool is capable of predicting stalls 5–20 ms before they occur. With a high-speed controller capable of 5 ms time-steps, mitigating action could be taken to prevent compressor stall before it occurs.

42 ENGINEERING↗
DOE OSTI2023

Effect of Cr and Ni concentrations on resilience of cast Nb- alloyed heat resistant austenitic steels at extreme high temperatures

Austenitic Cr–Ni alloyed heat resistant steels with Nb additions are used for intensively thermo-mechanically loaded cast components working in extreme high temperature oxidizing environment. Their performance during static oxidation and transient thermo-mechanical loading was investigated to recommend an optimal cost-effective Cr/Ni composition of Nb-alloyed austenitic class steels. Here, the static oxidation and transient thermo-mechanical behavior of three austenitic steels with different Cr/Ni alloying levels were investigated and compared for variety of working conditions. Static oxidation was performed between 900 °C and 1000 °C in air for 400 h. The critical temperature which increases spallation during static oxidation was determined for each of the steel alloying levels. In addition, thermal cycling of a constrained specimen was done with varying upper cycling temperatures between 850 °C and 1000 °C. SEM and TEM analyses were supported by thermodynamic simulation of the phases precipitated in the metal matrix and the structure of formed oxide layers. These studies were used to determine the mechanisms of degradation of thermo-mechanically loaded Cr/Ni austenitic steels at extreme high temperatures. A recommendation for a cost-effective Cr/Ni alloying level for different working conditions was determined.

36 MATERIALS SCIENCE↗
DOE OSTI2021

OC6 Phase Ib: Floating Wind Component Experiment for Difference-Frequency Hydrodynamic Load Validation

A new validation campaign was conducted at the W2 Harold Alfond Ocean Engineering Laboratory at the University of Maine to investigate the hydrodynamic loading on floating offshore wind substructures, with a focus on the low-frequency contributions that tend to drive extreme and fatigue loading in semisubmersible designs. A component-level approach was taken to examine the hydrodynamic loads on individual parts of the semisubmersible in isolation and then in the presence of other members to assess the change in hydrodynamic loading. A variety of wave conditions were investigated, including bichromatic waves, to provide a direct assessment of difference-frequency wave loading. An assessment of the impact of wave uncertainty on the loading was performed, with the goal of enabling validation with this dataset of numerical models with different levels of fidelity. The dataset is openly available for public use and can be downloaded from the U.S. Department of Energy Data Archive and Portal.

17 WIND ENERGY↗
DOE OSTI2021

Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design

In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Uncontrolled Electric Vehicle Charging Impacts on Distribution Electric Power Systems with Primarily Residential, Commercial or Industrial Loads

An increase in Electric Vehicles (EV) will result in higher demands on the distribution electric power systems (EPS) which may result in thermal line overloading and low voltage violations. To understand the impact, this work simulates two EV charging scenarios (home- and work-dominant) under potential 2030 EV adoption levels on 10 actual distribution feeders that support residential, commercial, and industrial loads. The simulations include actual driving patterns of existing (non-EV) vehicles taken from global positioning system (GPS) data. The GPS driving behaviors, which explain the spatial and temporal EV charging demands, provide information on each vehicles travel distance, dwell locations, and dwell durations. Then, the EPS simulations incorporate the EV charging demands to calculate the power flow across the feeder. Simulation results show that voltage impacts are modest (less than 0.01 p.u.), likely due to robust feeder designs and the models only represent the high-voltage (“primary”) system components. Line loading impacts are more noticeable, with a maximum increase of about 15%. Additionally, the feeder peak load times experience a slight shift for residential and mixed feeders (≈1 h), not at all for the industrial, and 8 h for the commercial feeder.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Regiospecific Cellulose Orientation and Anisotropic Mechanical Property in Plant Cell Walls

Cellulose microfibrils (CMFs) are a major load-bearing component in plant cell walls. Thus, their structures have been studied extensively with spectroscopic and microscopic characterization methods; but the findings from these two approaches were inconsistent, which hampers mechanistic understanding of cell wall mechanics. Here, we report the regiospecific assembly of CMFs in the periclinal wall of plant epidermal cells. Using sum frequency generation spectroscopic imaging, we found that CMFs are highly aligned in the cell edge region where two cells form a junction, whereas they are mostly isotropic on average throughout the wall thickness in the flat face region of the epidermal cell. This subcellular-level heterogeneity in CMF alignment provided insights into tissue-level anisotropy in tensile modulus of cell wall materials. Furthermore, this finding also has resolved a previous contradiction between the spectroscopic and microscopic imaging studies, which paves a foundation for better understanding of cell wall artichecture, especially structure-geometry relationships.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Machine Learning and IAST-Aided High-Throughput Screening of Cationic and Silica Zeolites for Alkane Capture, Storage, and Separations

We present an approach for quantitatively predicting the temperature-dependent single-component adsorption behavior of linear alkanes in silica and Na-exchanged cationic zeolites using machine learning (ML) models trained from extensive molecular simulations based on force fields with coupled cluster accuracy. A high-performing classification model was developed to distinguish between instances with negligible and non-negligible adsorption. Subsequently, two ML models were trained to predict the single-component adsorption loading and the heat of adsorption at any pressure at 300 K for any zeolite topology and silicon-to-aluminum ratio. The ML models were trained on International Zeolite Association (IZA) zeolites, and their transferability to hypothetical zeolites was successfully validated. We then expand the power of these predictions to adsorbed mixtures at arbitrary temperatures by integrating them with the Clausius–Clapeyron equation and ideal adsorbed solution theory (IAST). This approach was validated and then applied to a temperature swing adsorption separation process to demonstrate its practical utility. We demonstrate how predictions from this ML-enabled approach can allow the selection of high-performing materials that are then validated using detailed molecular simulations based on quantitatively accurate force fields.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Temperature effects of ion irradiation on the nanostructural features in ductile-phase-toughened tungsten composites

Ductile-phase toughened tungsten (DPT W) composites have emerged as promising candidates for load-bearing components behind the plasma-facing tungsten armor in fusion reactors due to their enhanced thermomechanical properties. This study focuses on a composite consisting of W particles embedded in a ductile NiFeW solution matrix, hot-rolled to a thickness reduction of 87% (87R DPT W). Sequential irradiations with Ni2+ and He+ ions were performed to identical doses and helium concentrations at room temperature (RT) and 1273 K. Irradiation at RT produced no discernible nanostructural features due to the immobility of mono-vacancies, whereas cavity formation was observed at 973 K. At 1273 K, the W phase exhibited larger cavities, reduced cavity number density, and lower volumetric swelling compared to 973 K. Notably, nanosized NiFeW precipitates formed within the W phase at 1273 K, a phenomenon absent at 973 K. A new phase of cubic (NiFe)6W6C was also observed at the interphase boundary. In contrast, the NiFeW matrix showed no nanostructural changes at 1273 K, likely due to cavity dissociation. Separate irradiations at 1273 K indicated that Ni2+ ions induced precipitate formation in the W phase, while He+ ions exclusively caused cavity formation. The microstructure of 87R DPT W irradiated at RT and subsequently annealed at 1273 K closely resembled that of material irradiated directly at 1273 K. Like oxide-dispersion-strengthened steels, the observed nanoparticle-embedded W can inhibit dislocation propagation, potentially delaying the ductile-to-brittle transition temperature. These findings highlight the potential of NiFeW nanoparticle-reinforced W composites as irradiation-resistant materials for fusion reactors.

Jiang, Weilin (ORCID:0000000183028313)↗
DOE OSTI2020

Process Heating Assessments Using DOE’s Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite

Process heating is the most energy-intensive manufacturing process for most sectors of industry. To quantify energy savings from various energy conservation measures, the Department of Energy (DOE) sponsored the development of the Process Heating Assessment and Survey Tool (PHAST) and similar tools for other industrial systems in the early 2000s. It has been used extensively in the Save Energy Now Program’s Energy Savings Assessments and the Better Plants Program’s In-Plant Trainings. Since the initial development of the legacy tools, both computer operating systems and software development have evolved significantly. Thus, DOE has invested in the modernization of PHAST and other legacy software tools to create the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool suite. MEASUR offers a collection of software tools that can aid manufacturing facilities in improving the efficiency of energy systems and equipment (specifically pumps, fans, steam, and process heating) and in conducting “Energy Treasure Hunts”. Eventually, the tool will also add compressed air and process cooling systems. The Process Heating Assessment (PHA) module of MEASUR is an upgrade of the PHAST tool. PHA provides the means to model fuel-fired, steam-based, and electric process heating systems, covering process heating for most industrial plants in manufacturing sector. It also includes several key upgrades, including the ability to consider multi-component charge loads and account for several different areas of energy losses. The new tool includes a comprehensive flue gas calculator to quantify available heat and heat loss for various gaseous, liquid, and solid fuels and new heat loss calculators. It generates a report and a dynamic Sankey diagram to show the energy consumption in various areas of energy use. MEASUR has significantly improved the user experience by adopting a modern software design. This paper details the structure and workflow of PHA and presents a real-world case study to demonstrate energy savings quantification and MEASUR’s outstanding reporting capabilities.

Nimbalkar, Sachin U.↗
DOE OSTI2020

Structure, properties, and applications of polyacrylonitrile/carbon nanotube ( CNT ) fibers at low CNT loading

Abstract Bi‐component, polyacrylonitrile (PAN)/carbon nanotube (CNT) fibers were processed, at different core‐sheath area ratios, by gel spinning. A percolated CNT network at 10 wt% CNT in the sheath enhanced electrical conductivity as compared to the neat PAN fiber, while PAN polymer in the core contributed to the good mechanical properties. Fibers with relatively thin sheath allowed overall CNT loading as low as 3.7 wt% to be made with good electrical conductivity, and PAN stabilization by Joule heating was demonstrated. Such fibers with combined good mechanical properties and electrical conductivity can also potentially be used for electrical heating of fabrics, for making smart textiles, and for electromagnetic interference shielding.

Lu, Mingxuan↗
DOE OSTI2024

Impact of wake steering on loads of downstream wind turbines at an above-rated condition

Wake steering strategies often seek to gain power at the expense of increased fatigue loads. Here, we investigate the feasibility of applying wake steering at an above-rated condition. In such a condition, the farm is operating at rated power, and thus, increased power output is not the goal. Instead, wake steering is considered in the context of load reduction. We perform a sweep of wind directions and yaw misalignment angles, ranging from negative to positive values. This approach allows us to obtain trends and identify asymmetries in turbine response for symmetric scenarios. We use a wind farm consisting of five aligned IEA Wind 15-MW reference wind turbines, and analyze trends related to the blade-root, low-speed shaft, and tower-base moments, both in terms of standard deviation and damage equivalent loads. We show that for any given fixed wind direction, the turbines can be yawed such that the fatigue loads are reduced. Reductions of up to 5% (depending on the component) in terms of standard deviation and damage equivalent loads can be achieved by negatively yawing the turbine. A negative yaw misalignment has shown to be the direction of larger improvements. Such results contrast those found for below-rated conditions, where a positive yaw misalignment is typically preferred. However, since load reduction is not uniform across all component loads, more study and consideration is required before operational recommendations can be made.

17 WIND ENERGY↗
DOE OSTI2020

Architecture of a catalytically active homotrimeric plant cellulose synthase complex

Cellulose is an essential plant cell wall component and represents the most abundant biopolymer on Earth. Supramolecular plant cellulose synthase complexes organize multiple linear glucose polymers into microfibrils as load-bearing wall components. We determined the structure of a poplar cellulose synthase CesA homotrimer that suggests a molecular basis for cellulose microfibril formation. This complex, stabilized by cytosolic plant-conserved regions and helical exchange within the transmembrane segments, forms three channels occupied by nascent cellulose polymers. Secretion steers the polymers toward a common exit point, which could facilitate protofibril formation. CesA’s N-terminal domains assemble into a cytosolic stalk that interacts with a microtubule-tethering protein and may thus be involved in CesA localization. Here, our data suggest how cellulose synthase complexes assemble and provide the molecular basis for plant cell wall engineering.

59 BASIC BIOLOGICAL SCIENCES↗