Search NASA⌕ Search

SEARCH · Search NASA

Results for “Engineering prototypes”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 397 records · Page 22

Measuring the thermal conductivity of hydrogels with a bidirectional 3w method

Hydrogels are soft, water-absorbing polymer materials with diverse applications in biomedicine and agriculture. Recently, hydrogels have been proposed to encapsulate water-soluble phase change materials which store energy in their latent heat of solidification. In these applications, the thermal conductivity of these materials affects their performance. Few methods exist for measuring the thermal conductivity of small quantities of hydrogels. Here, we describe an implementation of the bidirectional 3w technique to measure the thermal conductivity of hydrogels with particular attention to their moisture content. Our implementation of the technique can probe sample volumes as little as ~20 mL and yields the thermal conductivity without requiring fitting of additional thermal parameters. We numerically simulate 3w sensor designs with frequency-domain 3-D models to quantify and reduce errors introduced by the choice of substrate and insulation layer thickness. Frequencies in the ~1−20 Hz range yield less error for the materials considered here. We verify our setup with measurements on water and report values for polyacrylamide and poly(2-acrylamido-2-methylpropane sulfonic acid) (PAMPS) hydrogels. Our swollen hydrogels exhibited thermal conductivities nearly equivalent to water, 0.6 W m-1 K-1, and we estimate thermal conductivities of 0.43 and 0.42 W m-1 K-1 for neat polyacrylamide and PAMPS, respectively. Finally, we estimate an error of ±7%, consistent with other 3ω methods, with the largest error coming from the sensor calibration. We find our implementation of the bidirectional 3w method gives reasonable results and can be employed for prototyping soft materials relevant for thermal storage.

3-omega, thermal conductivity, hydrogel, moisture ↗

Lab-Scale Demonstration of Plutonium Purification by Anion Exchange, Plutonium(IV) Oxalate Precipitation, and Calcination to Plutonium Oxide to Support the MOX Feed Mission

H-Canyon and HB-Line are tasked with the production of PuO 2 from a feed of plutonium metal. The PuO 2 will provide feed material for the MOX Fuel Fabrication Facility. After dissolution of the Pu metal in H-Canyon, the solution will be transferred to HB-Line for purification by anion exchange. Subsequent unit operations include Pu(IV) oxalate precipitation, filtration and calcination to form PuO 2 . This report details the results from SRNL anion exchange, precipitation, filtration, calcination, and characterization tests, as requested by HB-Line1 and described in the task plan. This study involved an 80-g batch of Pu and employed test conditions prototypical of HB-Line conditions, wherever feasible. In addition, this study integrated lessons learned from earlier anion exchange and precipitation and calcination studies. H-Area Engineering selected direct strike Pu(IV) oxalate precipitation to produce a more dense PuO 2 product than expected from Pu(III) oxalate precipitation. One benefit of the Pu(IV) approach is that it eliminates the need for reduction by ascorbic acid. The proposed HB-Line precipitation process involves a digestion time of 5 minutes after the time (44 min) required for oxalic acid addition. These were the conditions during HB-line production of neptunium oxide (NpO 2 ). In addition, a series of small Pu(IV) oxalate precipitation tests with different digestion times were conducted to better understand the effect of digestion time on particle size, filtration efficiency and other factors. To test the recommended process conditions, researchers performed two nearly-identical larger-scale precipitation and calcination tests. The calcined batches of PuO 2 were characterized for density, specific surface area (SSA), particle size, moisture content, and impurities. Because the 3013 Standard requires that the calcination (or stabilization) process eliminate organics, characterization of PuO 2 batches monitored the presence of oxalate by thermogravimetric analysis-mass spectrometry (TGA-MS). To use the TGA-MS for carbon or oxalate content, some method development will be required. However, the TGA-MS is already used for moisture measurements. Therefore, SRNL initiated method development for the TGA-MS to allow quantification of oxalate or total carbon. That work continues at this time and is not yet ready for use in this study. However, the collected test data can be reviewed later as those analysis tools are available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

High Efficiency Integrated Package

Solid-state lighting based on LEDs has emerged as a superior alternative to inefficient conventional lighting, particularly incandescent. LED lighting can lead to 80 percent energy savings; can last 50,000 hours – 2-50 times longer than most bulbs; and contains no toxic lead or mercury. However, to enable mass adoption, particularly at the consumer level, the cost of LED luminaires must be reduced by an order of magnitude while achieving superior efficiency, light quality and lifetime. To become viable, energy-efficient replacement solutions must deliver system efficacies of ≥ 100 lumens per watt (LPW) with excellent color rendering (CRI > 85) at a cost that enables payback cycles of two years or less for commercial applications. This development will enable significant site energy savings as it targets commercial and retail lighting applications that are most sensitive to the lifetime operating costs with their extended operating hours per day. If costs are reduced substantially, dramatic energy savings can be realized by replacing incandescent lighting in the residential market as well. In light of these challenges, Cree proposed to develop a multi-chip integrated LED package with an output of > 1000 lumens of warm white light operating at an efficacy of at least 128 LPW with a CRI > 85. This product will serve as the light engine for replacement lamps and luminaires. At the end of the proposed program, this integrated package was to be used in a proof-of-concept lamp prototype to demonstrate the component’s viability in a common form factor. During this project Cree SBTC developed an efficient, compact warm-white LED package with an integrated remote color down-converter. Via a combination of intensive optical, electrical, and thermal optimization, a package design was obtained that met nearly all project goals. This package emitted 1295 lm under instant-on, room-temperature testing conditions, with an efficacy of 128.4 lm/W at a color temperature of ~2873K and 83 CRI. As such, the package’s performance exceeds DOE’s warm-white phosphor LED efficacy target for 2013. At the end of the program, we assembled an A19 sized demonstration bulb housing the integrated package which met Energy Star intensity variation requirements. With further development to reduce overall component cost, we anticipate that an integrated remote converter package such as developed during this program will find application in compact, high-efficacy LED-based lamps, particularly those requiring omnidirectional emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Final Technical Report: Thermoelectric-Enhanced Cookstove Add-on (TECA) for Clean Biomass Cookstoves

This program seeks to demonstrate a solution to enhance existing biomass cookstove performance through the use of RTI’s Thermoelectric Enhanced Cookstove Add-on (TECA) device. The self-powered TECA device captures a portion of heat from the stove and converts it to electricity through a thermoelectric (TE) device to power a blower. Colorado State University and Envirofit International are partners to support the air injection design and commercialization to enhance combustion in the stove and reduce emissions. Relevance: By demonstrating a proof of concept of the approach with the Envirofit M-5000 stove and TECA device, we hope to apply this technology to existing stoves that are already in use and reduce emissions for stoves that have already found user acceptance to provide a true health benefit. Challenges: The technical challenges include achieving Tier 4 emissions from a biomass stove and for such a stove to operate reliably in the harsh field environment. Additional challenges include the fact that it is difficult to develop a cost effective solution and insure adoption and proper use in the field. Outcomes: In this program we have demonstrated PM emissions at 82 mg/MJd, a 70% reduction as compared to baseline stove operation. We have also developed a stove optimization approach that reduces the number of costly experiments. We have evaluated component-level reliability and will be testing the stove prototype in the field for performance and reliability.

09 BIOMASS FUELS↗

Soft Matter Thermal and Mechnical Devices

The participant company, Treau, makes homes and buildings more comfortable with quiet, energy efficient, and easy to install heating and cooling systems. They entered the Cyclotron Road program with an idea for a heat exchanger and compressor and a general idea that the building heating and cooling sector was the best first target market. While at Cyclotron Road, they used the Cyclotron Road program staff and Berkeley Lab expertise to better understand the needs of the heating and cooling equipment market. This was critical to understand who the end customer was, and what features were needed in this market. They were then able to conduct product development with this target market/customer in mind. The Cyclotron Road program was also critical in building a manufacturing and scale-up plan that allowed the participant to build a credible growth and fundraising strategy. By the end of the program, the participant had a working prototype testing at Berkeley Lab’s HVAC testing facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Weapons Production Directorate Overview

Detonator Production and Prototype Fabrication divisions serve a variety of organizations throughout the Laboratory and the nation by providing key non-nuclear components through excellence in on-site engineering, design, manufacturing, machining, and more.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Q-18: Advanced System Development Fact Sheet

Q-18 provides Systems and Design Engineering for Future Weapons Systems and Technology up to Phase 3 or 6.3 with emphasis on improved performance, safety, produceability and agility of the future stockpile. The group regulars engages and partners with DoD customers, NNSA as well as other divisions across the LANL campus including to complete its mission. The group is forward leaning and provides Future System and System Agnostic Design and System Engineering support to a wide range of experiments from internally fielded technology tests to hydrodynamic and subcritical experiments including fabrication for small component level to full scale prototypes and test articles, test article assembly, and mechanical and electrical design.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

The Building ENergy Demand (BEND) Model: A Comprehensive Composite Building Energy Modeling Framework

The Building ENergy Demand (BEND) model was developed at Pacific Northwest National Laboratory (PNNL) to simulate climate-dependent hourly building energy demand with the ability to disaggregate down to or aggregate up to any geographic area of interest, including counties, states, electric utility service territories, and census regions. The BEND modeling framework is designed to study the effects of climate change, economics, technology advancement, and various mitigation policies on aggregate building energy demand. To make the process computationally feasible, BEND reduces granularity in building characteristics and weather forcing while maintaining enough detail to minimize systematic differences (biases) between BEND results and data from the Energy Information Administration (EIA). Based on the Commercial Building Energy Consumption Survey (CBECS) and Residential Energy Consumption Survey (RECS) databases, BEND establishes a set of representative buildings with predefined sets of building types, sizes, and vintages. These representative buildings are defined for each of the four U.S. census regions and the five climate zones used by the EIA for building surveys (hereafter “EIA climate zones”). BEND’s representative buildings are based on a statistical analysis of the CBECS and RECS databases that infers detailed parameters such as construction type, thermal properties, internal loads, equipment and mechanical systems, and operation schedules from the high-level descriptors in those databases (building type, vintage, size, and location). The representative buildings are simplified and consolidated into a set of prototype buildings for the purpose of simulating building energy demand. Combining the prototype buildings with weather files from selected locations and years, BEND creates a set of simulation-ready building models to be run using the EnergyPlus simulation engine (EnergyPlus). The base spatial unit of each BEND simulation is a subregion that is the intersection of an International Energy Conservation Code climate zone, a census region, and an EIA climate zone; analysis for each spatial unit is influenced by the weather file BEND selects to represent the climate-similar area. The major simulation outputs of interest to BEND are hourly energy consumption values for each simulated year, possibly for multiple fuel types. Based on building-stock weights derived from the CBECS/RECS data, the hourly output streams are aggregated to a single, 8760-hour load profile for each of the major building categories—residential and commercial—with the possibility of segregating by fuel types. To correct for biases inherent in the use of a limited suite of representative buildings, BEND is calibrated against observational targets of total annual building energy consumption and hourly load profiles (including peak demand) obtained for the decision-relevant geographic scales of interest (e.g., total electric load data for individual balancing authorities available from EIA). Based on available data such as population distribution, BEND is able to aggregate both up and down scales, allowing the study of building energy demand over a range of spatial scales (e.g., states or counties within the Western Electricity Coordinating Council, Eastern Interconnection, or the entire U.S.) and/or subsets of building types (e.g., office buildings with particular size ranges).

24 POWER TRANSMISSION AND DISTRIBUTION↗

Linker Vacancy Engineering of a Robust ftw–type Zr–MOF for Hexane Isomers Separation

Discrimination of physically similar molecules by porous solids represents an important yet challenging task in industrially relevant chemical separations. Precisely controlled pore dimension and/or tailored pore surface functionality are crucial to achieve high-efficiency separation. Metal-organic frameworks (MOFs) are promising candidates for these challenging separations in light of their structural diversity as well as highly adjustable pore dimension/functionality. We report here a microporous, ftw-type Zr-based MOF structure, HIAM-410 (HIAM=Hoffmann Institute of Advanced Materials), built on hexanuclear Zr 6 cluster and pyrene-1,3,6,8-tetracarboxylate (ptc 4– ). Its crystallographic structure has been determined using continuous rotation electron diffraction (cRED) technique combined with Rietveld refinement against powder X-ray diffraction data, aided by low-dose high-resolution transmission electron microscopy (HRTEM) imaging. The compound features exceptional framework stability that is comparable to the prototype MOF UiO-66. Interestingly, the linker vacancies in the pristine MOF structure could be partially restored by post-synthetic linker insertion. Its separation capability of hexane isomers is enhanced substantially upon the linker vacancy engineering. As a result, the restored structure exhibits efficient splitting of monobranched and dibranched hexane isomers at both room temperature and industrially relevant temperature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High Efficiency OLED Light Engine

LED Specialists has accomplished the program objective in designing a high efficiency OLED light engine combining high-performance OLED panels in the 5W-8W range. We achieved our goal by using an Active-Clamp Flyback circuit topology using state-of-the-art electronics. Evaluation testing of our second-generation prototype PC board has demonstrated an efficiency rating of 93% and dimming capability between 100% and 5% of OLED brightness. A reliability analysis of the design shows it to have a predicted Mean Time Between Failures (MTBF) of approximately 1,000,000 hours.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DE-FE0031180 Final Report - LGFCS Prototype System Testing - R0

In the project, LGFCS assembled and tested its modular SOFC Power System that incorporates all critical technology improvements identified for its “product-like” demonstration. This product demonstrator is expected to meet customer and LGFCS performance expectations for operation, availability, durability and serviceability. The principal technology improvements are aimed at increasing the fuel cell power output and reducing the stack degradation rate. Improvements were also made for added system robustness and increased reliability. The objective of this program is to test a 250kWe thermally self-sustaining modular solid oxide fuel cell (SOFC) Power System for a minimum of 5,000 hours while advancing this commercial prototype product demonstrator to a Technical Readiness Level (TRL) 7. The SOFC system was tested on a site provided by Stark State College in North Canton, Ohio. System performance and degradation as well as cost estimates were compared to established SOFC Program performance metrics to assess progress. The major achievements were to assemble, and QA qualify 70 fuel cell strips for 12 integrated blocks into a fuel cell vessel and install it into a generator module with the fuel and power electronics modules on the test site. Performance to date included over 1800 hours on load at 250 KW-AC to the grid with a DC efficiency of 61% and AC efficiency of 55%. Power degradation was less than 0.4% per 1000 hours and NOx emissions met standards. The LGFCS SOFC Prototype System (GEN0) was demonstrated in an operational environment and therefore achieving Technical Readiness Level 7. The work presented here represents the efforts of all the employees of LG Fuel Cell Systems. Their dedication and hard work made GEN0 possible and successful.

03 NATURAL GAS↗

Resolving the phase of Fano resonance wave packets with photoelectron frequency-resolved optical gating

The creation of structured electronic wave packets (EWPs) energetically close to Fano resonances has been achieved with ultrafast extreme ultraviolet coherent light sources. However, direct real-time observations of EWP evolution and full reconstructions of the quantum properties of EWPs, including both amplitude and phase, are lacking. Here we introduce and demonstrate a comprehensive approach for the direct measurement and complete characterization of structured EWPs created within a prototypical Fano resonance. Because of its analogy with frequency-resolved optical gating (FROG), we named the method photoelectron FROG. The correlated EWP is initiated by a carefully engineered extreme UV pump pulse. A weak near-infrared laser field, serving as a probe pulse, samples the evolution of the EWPs in the time domain, as well as in the frequency domain. The amplitude and phase of the EWPs are obtained via a time-dependent reconstruction algorithm based on a short-time Fourier transformation. Given the excellent agreement between our experimental results and time-dependent reconstructions, we expect this method to be broadly applicable to the study of ultrafast processes, especially electronic ones, in complex systems, as well as the coherent control of such systems on their fundamental timescales.

quantum optics↗

Atomic-scale strain manipulation of a charge density wave

Significance Charge density waves (CDWs) are simple periodic reorganizations of charge in a crystal, and yet they are still poorly understood and continue to bear surprises. External perturbations, such as strain or pressure, can in principle push a CDW phase into a different ordering geometry. However, engineering this type of quantum criticality has been experimentally challenging. Here, we implement a simple method for straining bulk materials. By applying it to 2H -NbSe 2 , a prototypical CDW system studied for decades, we discover two dramatic strain-induced CDW phase transitions. Our atomic-scale spectroscopic imaging measurements, combined with theory, reveal the distinct roles of electrons and phonons in forming these emergent states, thus opening a window into the rich phenomenology of CDWs.

74 ATOMIC AND MOLECULAR PHYSICS↗

A Mesh-Free Method to Predictively Simulate Solid-to-Liquid Phase Transitions in Abnormal Thermal Environments

Particle methods in computational physics are useful for modeling the motion of fluids and solids subject to large deformations. Under these conditions, mesh-based approaches often fail due to decreasing element quality leading to inaccuracy and instability. The developed software package called Moab investigates and prototypes next-generation particle methods, focusing on rigorous error analysis and active error minimization strategies during the computation. The present work discusses examples calculations representative of real engineering problems with quantified and maximized accuracy while demonstrating the potential for meeting engineering performance requirements.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Prototype Development for MBSE-Driven Digital Environment at Fermilab

Complex projects like Fermilab s accelerators and detectors involve thousands of interdependent components and requirements, making traditional documentation hard to keep consistent and often causing rework. Model-Based Systems Engineering (MBSE) tackles this by representing the system as a digital, queryable model. While widely used in aerospace and safety-critical industries, MBSE adoption has been limited elsewhere due to steep learning curves and high costs. This project investigates how a web-first, low-code MBSE stack can reduce those barriers and offer an accessible, unified source of truth for engineers and physicists.

Valle, Diego Pedro (ORCID:0009000865900663)↗

Rapid prototyping of microchannels with surface patterns for fabrication of polymer fibers

Microfluidic technology has provided innovative solutions to numerous problems, but the cost of designing and fabricating microfluidic channels is impeding its expansion. In this study, Shrinky-Dink thermoplastic sheets are used to create multilayered complex templates for microfluidic channels. We also used inkjet and laserjet printers to raise a predetermined microchannel geometry by depositing several layers of ink for each feature consecutively. We achieved feature heights over 100 μm, which were measured and compared with surface profilometry. Templates closest to the target geometry were then used to create microfluidic devices from soft-lithography with the molds as a template. These microfluidic devices were, futhermore used to fabricate polymer microfibers using the microfluidic focusing approach to demonstrate the potential that this process has for microfluidic applications. Finally, an economic analysis was conducted to compare the price of common microfluidic template manufacturing methods. We showed that multilayer microchannels can be created significantly quicker and cheaper than current methods for design prototyping and point-of-care applications in the biomedical area.

42 ENGINEERING↗

A Compact 50kW High Power Density, Hybrid 3-Level Paralleled T-type Inverter for More Electric Aircraft Applications

The demand for high performing, lightweight, reliable inverters, increased the scope of wide bandgap and high-switching frequency based solutions. To achieve such high efficiency inverters, it is vital to focus on the system level design considerations to maximize the benefits of these advanced technologies. This paper presents an improved design based on considerations to further reap the benefits of choosing the right inverter topology; increased capabilities through paralleling devices, with reduced total number of switches; and designing a planarized inverter with PCB based busbar. Appropriate thermal analysis and heatsink design has aided in increased system power density along with the overall efficiency. Demonstration of a 50kW 3-phase 3-level paralleled T-type SiC inverter operating at 40kHz switching frequency for aircraft applications is shown to evaluate the benefits of proposed design methodology. Here, the prototype achieves a high power density of 11kW/L.

42 ENGINEERING↗