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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Discrepant wear behavior of carbon nanotubes (CNTs) and dispersant in four-ball unidirectional and ball-on-flat reciprocating sliding tests

Carbon nanotubes (CNTs), basically rolled graphene sheets, have been studied lately as oil additives in the literature. However, we observed discrepant impact of CNTs on wear protection from two common tribological tests, four-ball unidirectional sliding and high frequency reciprocating rig (HFRR) ball-on-flat reciprocating sliding. To gain a stable suspension and dispersion of the CNTs in the oil, the CNT surface was functionalized with a phenyl ligand and a dispersant, polyisobutylene succinimide (PIBSI), was added. In the four-ball test, PIBSI alone failed to protect the surface but the CNTs effectively reduced the wear loss. The observations in the HFRR test however were the opposite: the PIBSI alone provided strong wear reduction but the CNTs had no positive impact. Here, such a discrepancy was hypothetically attributed to the different wear protection mechanisms by the PIBSI and CNTs which responded distinctively under different testing conditions. Additional unidirectional and reciprocating sliding tests with matching Hertzian contact pressures were able to validate the hypothesis. Worn surface morphological examination and tribofilm chemical analysis further supported the proposed wear mechanisms. Fundamental understanding gained in this study provides insights into the potential benefits and limitations of using CNTs in lubrication.

36 MATERIALS SCIENCE↗
NASA NTRS2010

Foldable Instrumented Bits for Ultrasonic/Sonic Penetrators

Long tool bits are undergoing development that can be stowed compactly until used as rock- or ground-penetrating probes actuated by ultrasonic/sonic mechanisms. These bits are designed to be folded or rolled into compact form for transport to exploration sites, where they are to be connected to their ultrasonic/ sonic actuation mechanisms and unfolded or unrolled to their full lengths for penetrating ground or rock to relatively large depths. These bits can be designed to acquire rock or soil samples and/or to be equipped with sensors for measuring properties of rock or soil in situ. These bits can also be designed to be withdrawn from the ground, restowed, and transported for reuse at different exploration sites. Apparatuses based on the concept of a probe actuated by an ultrasonic/sonic mechanism have been described in numerous prior NASA Tech Briefs articles, the most recent and relevant being "Ultrasonic/ Sonic Impacting Penetrators" (NPO-41666) NASA Tech Briefs, Vol. 32, No. 4 (April 2008), page 58. All of those apparatuses are variations on the basic theme of the earliest ones, denoted ultrasonic/sonic drill corers (USDCs). To recapitulate: An apparatus of this type includes a lightweight, low-power, piezoelectrically driven actuator in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that the size of the axial force needed to make the tool bit advance into soil, rock, or another material of interest is much smaller than in ordinary twist drilling, ordinary hammering, or ordinary steady pushing. Examples of properties that could be measured by use of an instrumented tool bit include electrical conductivity, permittivity, magnetic field, magnetic permeability, temperature, and any other properties that can be measured by fiber-optic sensors. The problem of instrumenting a probe of this type is simplified, relative to the problem of attaching electrodes in a rotating drill bit, in two ways: (1) Unlike a rotating drill bit, a bit of this type does not have flutes, which would compound the problem of ensuring contact between sensors and the side wall of a hole; and (2) there is no need for slip rings for electrical contact between sensor electronic circuitry and external circuitry because, unlike a rotating drill, a tool bit of this type is not rotated continuously during operation. One design for a tool bit of the present type is a segmented bit with a segmented, hinged support structure (see figure). The bit and its ultrasonic/sonic actuator are supported by a slider/guiding fixture, and its displacement and preload are controlled by a motor. For deployment from the folded configuration, a spring-loaded mechanism rotates the lower segment about the hinges, causing the lower segment to become axially aligned with the upper segment. A latching mechanism then locks the segments of the bit and the corresponding segments of the slider/guiding fixture. Then the entire resulting assembly is maneuvered into position for drilling into the ground. Another design provides for a bit comprising multiple tubular segments with an inner alignment string, similar to a foldable tent pole comprising multiple tubular segments with an inner elastic cable connecting the two ends. At the beginning of deployment, all segments except the first (lowermost) one remain folded, and the ultrasonic/sonic actuator is clamped to the top of the lowermost segment and used to drive this segment into the ground. When the first segment has penetrated to a specified depth, the second segment is connected to the upper end of the first segment to form a longer rigid tubular bit and the actuator is moved to the upper end of the second segnt. The process as described thus far is repeated, adding segments until the desired depth of penetration has been attained. Yet other designs provide for bits in the form of bistable circular- or rectangular- cross-section tubes that can be stowed compactly like rolls of flat tape and become rigidified upon extension to full length, in a manner partly similar to that of a common steel tape measure. Albeit not marketed for use in tool bits, a bistable reeled composite product that transforms itself from a flat coil to a rigid tube of circular cross section when unrolled, is commercially available under the trade name RolaTube(TradeMark) and serves as a model for the further development of tool bits of this subtype.

Bar-Cohen, Yoseph↗
DOE OSTI2013

PETSc Users Manual (Rev. 3.3)

This manual describes the use of PETSc for the numerical solution of partial differential equations and related problems on high-performance computers. The Portable, Extensible Toolkit for Scientific Computation (PETSc) is a suite of data structures and routines that provide the building blocks for the implementation of large-scale application codes on parallel (and serial) computers. PETSc uses the MPI standard for all message-passing communication. PETSc includes an expanding suite of parallel linear, nonlinear equation solvers and time integrators that may be used in application codes written in Fortran, C, C++, Python, and MATLAB (sequential). PETSc provides many of the mechanisms needed within parallel application codes, such as parallel matrix and vector assembly routines. The library is organized hierarchically, enabling users to employ the level of abstraction that is most appropriate for a particular problem. By using techniques of object-oriented programming, PETSc provides enormous flexibility for users. PETSc is a sophisticated set of software tools; as such, for some users it initially has a much steeper learning curve than a simple subroutine library. In particular, for individuals without some computer science background, experience programming in C, C++ or Fortran and experience using a debugger such as gdb or dbx, it may require a significant amount of time to take full advantage of the features that enable efficient software use. However, the power of the PETSc design and the algorithms it incorporates may make the efficient implementation of many application codes simpler than “rolling them” yourself; For many tasks a package such as MATLAB is often the best tool; PETSc is not intended for the classes of problems for which effective MATLAB code can be written. PETSc also has a MATLAB interface, so portions of your code can be written in MATLAB to “try out” the PETSc solvers. The resulting code will not be scalable however because currently MATLAB is inherently not scalable; and PETSc should not be used to attempt to provide a “parallel linear solver” in an otherwise sequential code. Certainly all parts of a previously sequential code need not be parallelized but the matrix generation portion must be parallelized to expect any kind of reasonable performance. Do not expect to generate your matrix sequentially and then “use PETSc” to solve the linear system in parallel. Since PETSc is under continued development, small changes in usage and calling sequences of routines will occur. PETSc is supported; see the web site http://www.mcs.anl.gov/petsc for information on contacting support. A http://www.mcs.anl.gov/petsc/publications may be found a list of publications and web sites that feature work involving PETSc. We welcome any reports of corrections for this document.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

PETSc Users Manual (Rev. 3.4)

This manual describes the use of PETSc for the numerical solution of partial differential equations and related problems on high-performance computers. The Portable, Extensible Toolkit for Scientific Computation (PETSc) is a suite of data structures and routines that provide the building blocks for the implementation of large-scale application codes on parallel (and serial) computers. PETSc uses the MPI standard for all message-passing communication. PETSc includes an expanding suite of parallel linear, nonlinear equation solvers and time integrators that may be used in application codes written in Fortran, C, C++, Python, and MATLAB (sequential). PETSc provides many of the mechanisms needed within parallel application codes, such as parallel matrix and vector assembly routines. The library is organized hierarchically, enabling users to employ the level of abstraction that is most appropriate for a particular problem. By using techniques of object-oriented programming, PETSc provides enormous flexibility for users. PETSc is a sophisticated set of software tools; as such, for some users it initially has a much steeper learning curve than a simple subroutine library. In particular, for individuals without some computer science background, experience programming in C, C++ or Fortran and experience using a debugger such as gdb or dbx, it may require a significant amount of time to take full advantage of the features that enable efficient software use. However, the power of the PETSc design and the algorithms it incorporates may make the efficient implementation of many application codes simpler than “rolling them” yourself; For many tasks a package such as MATLAB is often the best tool; PETSc is not intended for the classes of problems for which effective MATLAB code can be written. PETSc also has a MATLAB interface, so portions of your code can be written in MATLAB to “try out” the PETSc solvers. The resulting code will not be scalable however because currently MATLAB is inherently not scalable; and PETSc should not be used to attempt to provide a “parallel linear solver” in an otherwise sequential code. Certainly all parts of a previously sequential code need not be parallelized but the matrix generation portion must be parallelized to expect any kind of reasonable performance. Do not expect to generate your matrix sequentially and then “use PETSc” to solve the linear system in parallel. Since PETSc is under continued development, small changes in usage and calling sequences of routines will occur. PETSc is supported; see the web site http://www.mcs.anl.gov/petsc for information on contacting support. A http://www.mcs.anl.gov/petsc/publications may be found a list of publications and web sites that feature work involving PETSc. We welcome any reports of corrections for this document.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

PETSc Users Manual (Rev. 3.5)

This manual describes the use of PETSc for the numerical solution of partial differential equations and related problems on high-performance computers. The Portable, Extensible Toolkit for Scientific Computation (PETSc) is a suite of data structures and routines that provide the building blocks for the implementation of large-scale application codes on parallel (and serial) computers. PETSc uses the MPI standard for all message-passing communication. PETSc includes an expanding suite of parallel linear, nonlinear equation solvers and time integrators that may be used in application codes written in Fortran, C, C++, Python, and MATLAB (sequential). PETSc provides many of the mechanisms needed within parallel application codes, such as parallel matrix and vector assembly routines. The library is organized hierarchically, enabling users to employ the level of abstraction that is most appropriate for a particular problem. By using techniques of object-oriented programming, PETSc provides enormous flexibility for users. PETSc is a sophisticated set of software tools; as such, for some users it initially has a much steeper learning curve than a simple subroutine library. In particular, for individuals without some computer science background, experience programming in C, C++ or Fortran and experience using a debugger such as gdb or dbx, it may require a significant amount of time to take full advantage of the features that enable efficient software use. However, the power of the PETSc design and the algorithms it incorporates may make the efficient implementation of many application codes simpler than “rolling them” yourself. ;For many tasks a package such as MATLAB is often the best tool; PETSc is not intended for the classes of problems for which effective MATLAB code can be written. PETSc also has a MATLAB interface, so portions of your code can be written in MATLAB to “try out” the PETSc solvers. The resulting code will not be scalable however because currently MATLAB is inherently not scalable; and PETSc should not be used to attempt to provide a “parallel linear solver” in an otherwise sequential code. Certainly all parts of a previously sequential code need not be parallelized but the matrix generation portion must be parallelized to expect any kind of reasonable performance. Do not expect to generate your matrix sequentially and then “use PETSc” to solve the linear system in parallel. Since PETSc is under continued development, small changes in usage and calling sequences of routines will occur. PETSc is supported; see the web site http://www.mcs.anl.gov/petsc for information on contacting support. A http://www.mcs.anl.gov/petsc/publications may be found a list of publications and web sites that feature work involving PETSc. We welcome any reports of corrections for this document.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2001

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction: Comparison of Bearing Life Theories - Part 1

Four rolling-element bearing life theories were chosen for analysis and compared for a simple roller-race geometry model. The life theories were those of Weibull; Lundberg and Palmgren; Ioannides and Harris; and Zaretsky. The analysis without a fatigue limit of Ioannides and Harris is identical to the Lundberg and Palmgren analysis, and the Weibull analysis is similar to that of Zaretsky if the exponents are chosen to be identical. The resultant predicted life a each stress condition not only depends on the life equation used but also on the Weibull slope assumed. The least variation in predicted life with Weibull slope comes with the Zaretsky equation. Except for a Weibull slope of 1.11, at which the Weibull equation predicts the highest lives, the highest lives are predicted for the Zaretsky equation. For Weibull slopes of 1.5 and 2, both the Lundherg-Palmgren and Ioannides-Harris (where tau(sub u) = 0) equations predict lower lives than the ANSI/ABMA/ISO standard. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field. The assumption of as shear stress fatigue limit tau(sub u) results in Hertz stress-life exponents greater than are experimentally verifiable.

Poplawski, Joseph V.↗
DOE OSTI2011

Tribology and Tool Wear of Hot Dip Galvanized Zinc Magnesium Alloys on Cold Rolled Steel Sheets

Recently zinc based coatings on cold rolled steel with improved functionality in terms of forming and/or corrosion behaviour have been intensively investigated in the steel industry. One of the most promising products are zinc magnesium alloys produced in hot dip galvanizing process. These coatings were already introduced in construction industry a few years ago. With some modifications the improved properties of the coating are also interesting for automotive industry. In the present work the tribological potential of hot dip galvanized zinc magnesium coatings (HDG/ZM) produced at an industrial line under regular production, was studied in terms of sliding properties, adhesive and abrasive tool wear.First a short introduction into surface morphology of HDG/ZM will be given. For the tribological characterization of the material, which is the main topic of the contribution, different tests were performed on hot dip galvanised zinc magnesium material and results were compared with classic hot dip galvanized zinc coating (HDG/Z). The investigations are mainly based on the strip draw test which allows the determination of the friction coefficient directly by using a constant contact pressure. Deep drawing property was tested by forming model cups. The abrasive tool wear was tested using a standard test for material used in automotive industry. The adhesive tool wear was investigated by characterizing the coating material transferred to the tool in the strip draw test.All performed tests show an improved drawability of HDG/ZM compared to classical HDG/Z reference material. However the most promising difference between HDG/ZM and HDG/Z is that galling was found to be less for HDG/ZM than for HDG/Z. Therefore HDG/ZM is an interesting system not only with respect to corrosion protection but also in terms of tribology and provides clear advantages in formability.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Fully Printed, Flexible, Phased Array Antenna for Lunar Surface Communication

NASAs future exploration missions focus on the manned exploration of the Moon, Mars, and beyond, which will rely heavily on the development of a reliable communications infrastructure from planetary surface-to-surface, surface-to-orbit, and back to Earth. Flexible antennas are highly desired in many scenarios. Active phased array antennas (active PAAs) with distributed control and processing electronics at the surface of an antenna aperture offer numerous advantages for radar communications. Large-area active PAAs on flexible substrates are of particular interest in NASA s space radars due to their efficient inflatable package that can be rolled up during transportation and deployed in space. Such an inflatable package significantly reduces stowage volume and mass. Because of these performance and packaging advantages, large-area inflatable active PAAs are highly desired in NASA s surface-to-orbit and surface-to-relay communications. To address the issues of flexible electronics, a room-temperature printing process of active phased-array antennas on a flexible Kapton substrate was developed. Field effect transistors (FETs) based on carbon nanotubes (CNTs), with many unique physical properties, were successfully proved feasible for the PAA system. This innovation is a new type of fully inkjet-printable, two-dimensional, high-frequency PAA on a flexible substrate at room temperature. The designed electronic circuit components, such as the FET switches in the phase shifter, metal interconnection lines, microstrip transmission lines, etc., are all printed using a special inkjet printer. Using the developed technology, entire 1x4, 2x2, and 4x4 PAA systems were developed, packaged, and demonstrated at 5.3 GHz. Several key solutions are addressed in this work to solve the fabrication issues. The source/drain contact is developed using droplets of silver ink printed on the source/drain areas prior to applying CNT thin-film. The wet silver ink droplets allow the silver to wet the CNT thin-film area and enable good contact with the source and drain contact after annealing. A passivation layer to protect the device channel is developed by bonding a thin Kapton film on top of the device channel. This film is also used as the media for transferring the aligned CNT thin-film on the device substrate. A simple and cost-effective technique to form multilayer metal interconnections on flexible substrate is developed and demonstrated. Contact vias are formed on the second substrate prior to bonding on the first substrate. Inkjet printing is used to fill the silver ink into the via structure. The printed silver ink penetrates through the vias to contact with the contact pads on the bottom layer. It is then annealed to form a good connection. One-dimensional and two-dimensional PAAs were fabricated and characterized. In these circuits, multilayer metal interconnects were used to make a complete PAA system.

Subbaraman, Harish↗
DOE OSTI2023

PETSc/TAO Users Manual (Rev. 3.19)

This manual describes the use of the Portable, Extensible Toolkit for Scientific Computation (PETSc) and the Toolkit for Advanced Optimization (TAO) for the numerical solution of partial differential equations and related problems on high-performance computers. PETSc/TAO is a suite of data structures and routines that provide the building blocks for the implementation of large-scale application codes on parallel (and serial) computers. PETSc uses the MPI standard for all distributed memory communication. PETSc/TAO includes a large suite of parallel linear solvers, nonlinear solvers, time integrators, and opti mization that may be used in application codes written in Fortran, C, C++, and Python (via petsc4py; see Getting Started). PETSc provides many of the mechanisms needed within parallel application codes, such as parallel matrix and vector assembly routines. The library is organized hierarchically, enabling users to employ the level of abstraction that is most appropriate for a particular problem. By using techniques of object-oriented programming, PETSc provides enormous flexibility for users. PETSc is a sophisticated set of software tools; as such, for some users it initially has a much steeper learning curve than packages such as MATLAB or a simple subroutine library. In particular, for individuals without some computer science background, experience programming in C, C++, python, or Fortran and experience using a debugger such as gdb or lldb, it may require a significant amount of time to take full advantage of the features that enable efficient software use. However, the power of the PETSc design and the algorithms it incorporates may make the efficient implementation of many application codes simpler than “rolling them” yourself. For many tasks a package such as MATLAB is often the best tool; PETSc is not intended for the classes of problems for which effective MATLAB code can be written. There are several packages, built on PETSc, that may satisfy your needs without requiring directly using PETSc. We recommend reviewing these packages functionality before starting to code directly with PETSc. PETSc can be used to provide a “MPI parallel linear solver” in an otherwise sequential, or OpenMP parallel code. This approach cannot provide extremely large improvements in the application time by utilizing large numbers of MPI processes but can still improve the performance. Certainly all parts of a previously sequential code need not be parallelized but the matrix generation portion must be parallelized to expect true scalability to large numbers of MPI processes. See PCMPI for details on how to utilize the PETSc MPI linear solver server. Since PETSc is under continued development, small changes in usage and calling sequences of routines will occur. PETSc has been supported for twenty-five years; see mailing list information on our website for information on contacting support.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Photonic curing of solution-deposited ZrO 2 dielectric on PEN: a path towards high-throughput processing of oxide electronics

High-throughput manufacturing of oxide electronics will enable new applications ranging from large-area displays to flexible medical devices and low-cost solar panels. However, high quality oxide films from solution-based precursors typically require 20 minutes or more of thermal annealing at high temperature (> 250 °C) for each layer, severely limiting both the throughput and substrate choice. Here, we report high speed photonic curing of ZrO 2 dielectric thin films on flexible plastic substrates. The curing and patterning processes can be achieved simultaneously by using shadow mask patterning or adjusting conditions to convert oxide only on top of underlying metal contacts, i.e. self-aligned patterning. Metal-insulator-metal capacitors using two layers of ZrO 2 films photonically cured in just 100 seconds per layer show non-dispersive capacitance-frequency behavior from 10 2 to 10 6 Hz, high areal capacitance of 200 nF/cm 2 and low dissipation factor of 0.03 at 10 5 Hz, leakage current density of ~ 10 -7 A/cm 2 at an applied field of 2 MV/cm, and a breakdown field of nearly 8 MV/cm. Using an upgraded tool, similar dielectric properties are achieved in as short as 100 milliseconds using a single pulse of light, revealing a pathway to oxide film processing beyond 30 m/min.

14 SOLAR ENERGY↗
DOE OSTI2021

WhiteWind: White Etching Crack (WEC) Bearing Failures in Wind Turbine: Cooperative Research and Development, CRADA Number CRD-18-00758 (Final Report)

A WEC is a particularly aggressive, unpredictable and wide spread rolling element bearing failure mode that is common for large multi-megawatt (MW) wind turbines. WEC is considered the single most expensive failure mode for all wind turbine components, and there is currently no commercial solution. The Technical University of Denmark (DTU) is leading the WhiteWind project to investigate WECs through funding provided by the Innovation Fund Denmark. Other project partners include Vestas, SKF, Expanite, Rheinisch-Westfalische Technische Hochschule Aachen University (RWTH Aachen), and Argonne National Laboratory. The objective of the overall project is to develop a new surface engineered WEC-resistant bearing material using novel surface engineering techniques that shall provide a commercially competitive alternative to existing wind turbine bearings. NREL will support the project by providing existing measured bearing loads and validating models of drivetrain loads.

17 WIND ENERGY↗
NASA NTRS2002

Optimal Aircraft Control Upset Recovery With and Without Component Failures

This paper treats the problem of recovering sustainable nondescending (safe) flight in a transport aircraft after one or more of its control effectors fail. Such recovery can be a challenging goal for many transport aircraft currently in the operational fleet for two reasons. First, they have very little redundancy in their means of generating control forces and moments. These aircraft have, as primary control surfaces, a single rudder and pairwise elevators and aileron/spoiler units that provide yaw, pitch, and roll moments with sufficient bandwidth to be used in stabilizing and maneuvering the airframe. Beyond this, throttling the engines can provide additional moments, but on a much slower time scale. Other aerodynamic surfaces, such as leading and trailing edge flaps, are only intended to be placed in a position and left, and are, hence, very slow-moving. Because of this, loss of a primary control surface strongly degrades the controllability of the vehicle, particularly when the failed effector becomes stuck in a non-neutral position where it exerts a disturbance moment that must be countered by the remaining operating effectors. The second challenge in recovering safe flight is that these vehicles are not agile, nor can they tolerate large accelerations. This is of special importance when, at the outset of the recovery maneuver, the aircraft is flying toward the ground, as is frequently the case when there are major control hardware failures. Recovery of safe flight is examined in this paper in the context of trajectory optimization. For a particular transport aircraft, and a failure scenario inspired by an historical air disaster, recovery scenarios are calculated with and without control surface failures, to bring the aircraft to safe flight from the adverse flight condition that it had assumed, apparently as a result of contact with a vortex from a larger aircraft's wake. An effort has been made to represent relevant airframe dynamics, acceleration limits, and actuator limits faithfully, since these contribute to the lack of agility and control power that plays an important role in defining what can be achieved with the vehicle when it is in extremis.

Sparks, Dean W.↗
DOE OSTI2012

NREL's Energy-Saving Technology for Air Conditioning Cuts Peak Power Loads Without Using Harmful Refrigerants (Fact Sheet)

This fact sheet describes how the DEVAP air conditioner was invented, explains how the technology works, and why it won an R&D 100 Award. Desiccant-enhanced evaporative (DEVAP) air-conditioning will provide superior comfort for commercial buildings in any climate at a small fraction of the electricity costs of conventional air-conditioning equipment, releasing far less carbon dioxide and cutting costly peak electrical demand by an estimated 80%. Air conditioning currently consumes about 15% of the electricity generated in the United States and is a major contributor to peak electrical demand on hot summer days, which can lead to escalating power costs, brownouts, and rolling blackouts. DEVAP employs an innovative combination of air-cooling technologies to reduce energy use by up to 81%. DEVAP also shifts most of the energy needs to thermal energy sources, reducing annual electricity use by up to 90%. In doing so, DEVAP is estimated to cut peak electrical demand by nearly 80% in all climates. Widespread use of this cooling cycle would dramatically cut peak electrical loads throughout the country, saving billions of dollars in investments and operating costs for our nation's electrical utilities. Water is already used as a refrigerant in evaporative coolers, a common and widely used energy-saving technology for arid regions. The technology cools incoming hot, dry air by evaporating water into it. The energy absorbed by the water as it evaporates, known as the latent heat of vaporization, cools the air while humidifying it. However, evaporative coolers only function when the air is dry, and they deliver humid air that can lower the comfort level for building occupants. And even many dry climates like Phoenix, Arizona, have a humid season when evaporative cooling won't work well. DEVAP extends the applicability of evaporative cooling by first using a liquid desiccant-a water-absorbing material-to dry the air. The dry air is then passed to an indirect evaporative cooling stage, in which the incoming air is in thermal contact with a moistened surface that evaporates the water into a separate air stream. As the evaporation cools the moistened surface, it draws heat from the incoming air without adding humidity to it. A number of cooling cycles have been developed that employ indirect evaporative cooling, but DEVAP achieves a superior efficiency relative to its technological siblings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2001

Carbon Nanotubes in Water: MD Simulations of Internal and External Flow, Self Organization

We have developed computational tools, based on particle codes, for molecular dynamics (MD) simulation of carbon nanotubes (CNT) in aqueous environments. The interaction of CNTs with water is envisioned as a prototype for the design of engineering nano-devices, such as artificial sterocillia and molecular biosensors. Large scale simulations involving thousands of water molecules are possible due to our efficient parallel MD code that takes long range electrostatic interactions into account. Since CNTs can be considered as rolled up sheets of graphite, we expect the CNT-water interaction to be similar to the interaction of graphite with water. However, there are fundamental differences between considering graphite and CNTs, since the curvature of CNTs affects their chemical activity and also since capillary effects play an important role for both dynamic and static behaviour of materials inside CNTs. In recent studies Gordillo and Marti described the hydrogen bond structure as well as time dependent properties of water confined in CNTs. We are presenting results from the development of force fields describing the interaction of CNTs and water based on ab-initio quantum mechanical calculations. Furthermore, our results include both water flows external to CNTs and the behaviour of water nanodroplets inside heated CNTs. In the first case (external flows) the hydrophobic behaviour of CNTs is quantified and we analyze structural properties of water in the vicinity of CNTs with diagnostics such as hydrogen bond distribution, water dipole orientation and radial distribution functions. The presence of water leads to attractive forces between CNTs as a result of their hydrophobicity. Through extensive simulations we quantify these attractive forces in terms of the number and separation of the CNT. Results of our simulations involving arrays of CNTs indicate that these exhibit a hydrophobic behaviour that leads to self-organising structures capable of trapping water clusters. In the second case (internal flows) we study the behaviour of water droplets confined inside CNTs. Constant temperature simulations allow us to capture structural properties such as the contact angles and density profiles of the equilibrated drops. By heating and subsequently cooling of the CNT, we are able to measure the evaporation and the condensation rate of the entrapped water.

Jaffe, Richard L.↗
NASA NTRS2007

Carbon Nanotubes for Space Photovoltaic Applications

Carbon nanotubes (CNTs) can be envisioned as an individual graphene sheet rolled into a seamless cylinder (single-walled, SWNT), or concentric sheets as in the case of a multi-walled carbon nanotube (MWNT) (1). The role-up vector will determine the hexagonal arrangement and "chirality" of the graphene sheet, which will establish the nanotube to be metallic or semiconducting. The optoelectronic properties will depend directly on this chiral angle and the diameter of the SWNT, with semiconductor types exhibiting a band gap energy (2). Characteristic of MWNTs are the concentric graphene layers spaced 0.34 nm apart, with diameters from 10-200 nm and lengths up to hundreds of microns (2). In the case of SWNTs, the diameters range from 0.4 - 2 nm and lengths have been reported up to 1.5 cm (3). SWNTs have the distinguishable property of "bundling" together due to van der Waal's attractions to form "ropes." A comparison of these different structural types is shown in Figure 1. The use of SWNTS in space photovoltaic (PV) applications is attractive for a variety of reasons. Carbon nanotubes as a class of materials exhibit unprecedented optical, electrical, mechanical properties, with the added benefit of being nanoscale in size which fosters ideal interaction in nanomaterial-based devices like polymeric solar cells. The optical bandgap of semiconducting SWNTs can be varied from approx. 0.4 - 1.5 eV, with this property being inversely proportional to the nanotube diameter. Recent work at GE Global Research has shown where a single nanotube device can behave as an "ideal" pn diode (5). The SWNT was bridged over a SiO2 channel between Mo contacts and exhibited an ideality factor of 1, based on a fit of the current-voltage data using the diode equation. The measured PV efficiency under a 0.8 eV monochromatic illumination showed a power conversion efficiency of 0.2 %. However, the projected efficiency of these junctions is estimated to be > 5 %, especially when one considers the enhanced absorption (from nanotubes whose bandgap is tailored to illumination) and electromagnetic coupling in a network of nanotubes.

Efstathiadis, Harry↗
DOE OSTI2018

Controlled High Filler Loading of Functionalized Al{sub 2}O{sub 3}-Filled Epoxy Composites for LED Thermal Management

Thermal management in light-emitting diode (LED) has been extensively researched recently. This study is intended to develop an effective thermally conductive epoxy composite as thermal interface material (TIM) for headlamp LEDs. Silane-functionalized aluminum oxide (Al{sub 2}O{sub 3}) powder of different average particle sizes (44 and 10 µm) was studied for its feasibility as filler at its maximum loading. A detailed comparison of three different methods of particle dispersions, hand-mix, speed-mix and calendaring process (3-roll mill), has been reported. The dispersion of Al{sub 2}O{sub 3} particles, the thermal conductivity and thermal degradation characteristics of the composites were investigated and explained in detail. At 75 wt.% filler loading, 10 and 44 µm Al{sub 2}O{sub 3} achieved composite thermal conductivities of 1.13 and 2.08 W/mK, respectively, which is approximately 528 and 1055% of enhancement with respect to neat epoxy. The package-level thermal performance of the LED employing the Al{sub 2}O{sub 3}-filled TIMs was carried out using thermal transient analysis. The experimental junction-to-ambient thermal resistances (R{sub thJ-A}) achieved were 6.65, 7.24, and 8.63 K/W for Al{sub 2}O{sub 3-44µm}, Al{sub 2}O{sub 3-10µm} and neat epoxy, respectively. The results revealed that the Al{sub 2}O{sub 3-44µm} fillers-filled composite performed better in both material-level and package-level thermal characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Validation of Combined Analytical Methods to Predict Slip in Cylindrical Roller Bearings

This paper presents a combination of models that together calculate the cage and roller speeds of a cylindrical roller bearing. The models consider elastohydrodynamic lubrication and contact elasticity between the roller and raceway, roller centrifugal forces, hydrodynamic lubrication at the cage pocket, and frictional forces. Using these models, the predicted cage and roller speeds and the extent of slip are compared to measurements acquired on cylindrical roller bearings in a commercial gearbox in steady-state and transient operating conditions of a wind turbine. In steady-state conditions at low wind speeds and low lubricant temperatures, cage and roller slip up to 60% occur in the loaded zone of the bearing. In the unloaded zone, up to 80% roller slip occurs. Cage and roller slip then decrease as the lubricant temperature and wind speed increases. In general, the analytical model results match experimental measurements within 10% for lubricant temperatures above 40 degrees C and wind speeds over 10 meters per second. The analytical model is further evaluated during a transient start-up event and highly dynamic emergency stop event and also used to examine changes in the bearing design or lubricant properties. Furthermore, roller and cage slip in cylindrical bearings is a combined effect of the bearing design, applied load, shaft speed, and lubricant properties and temperature, and can be quickly evaluated with the combined analytical models.

17 WIND ENERGY↗
DOE OSTI2018

Polyalkylene Glycol (PAG) Based Lubricant for Light & Medium Duty Axles

The axle lubricant (SAE 75W-140) widely used in the market place over the last few years is primarily formulated from polyalpha olefin (PAO) basestock. This investigation focused on polyalkylene glycol (PAG) base stock which is significantly different chemically from PAO and because of their polar nature it is hypothesized that it can adsorb relatively easily on contacting surfaces resulting in significant friction reduction and improve fuel economy. Axle efficiency is generally quite high at high torque range but it could be quite low at low torque range representative of EPA drive cycles. Therefore, this project primarily focus on improving axle efficiency in the low torque range while maintaining all durability attributes. The objective of this project is to develop novel lubricant formulations that are expected to improve the fuel efficiency of light, medium, heavy-duty, and military vehicles by at least 2% over Society of Automotive Engineers (SAE) 75W-140 axle lubricants (improvement based on comparative results from engine dynamometer testing, chassis dynamometer testing or test track, e.g., SAE J1321) without adverse impacts on vehicle performance or durability. The proposed research project followed a structured approach beginning with lubricant formulations by varying base oil chemistry and additive components followed by physical property characterization. Lubricant performance evaluations started with simple laboratory friction, wear, oxidation, and corrosion tests which guided into identification of performance areas requiring improvements. This required an iterative lubricant reformulation. Once a few acceptable formulations were identified, they are evaluated in more complex component tests including ASTM tests (L-37 - load carrying capacity under low speed and high torque, L42 – load carrying properties under high speed and shock loading, L-60 - thermal and oxidative stability, and L-33-1 moisture corrosion resistance). Two issues were observed following L-42 tests; toxicological and foaming. This required reformulation and repeating all ASTM tests. During repeat tests it was observed that some of the additives precipitated out of solution. Since it was discovered quite late in the program, and the time it may need to find a solution to this issue, the team changed direction of the program to switch to use of an oil soluble PAG as a co-basestock (15-30%) with mineral oil used in a commercial formulation (SAE 75W-85). This formulation strategy helped passing all ASTM tests. This was followed by Ford proprietary axle efficiency, gear wear, and chassis roll dynamometer tests for fuel economy evaluations. Axle efficiency was improved up to 7% when a full PAG formulation was used but no such significant improvement was observed with PAG as co-basestock formulation. Chassis roll fuel economy improved by 1.9% with PAG co-basestock formulation (conforming to SAE 75W-85) compared to SAE 75W-140 baseline. However, it was observed that the improvement is mostly due to reduced viscosity of candidate formulation when compared to a full mineral oil based SAE 75W-85 formulation. PAG as co-basestock also exhibited unacceptable wear in proprietary gear wear test. This investigation highlighted challenges with PAG formulations including identification of additive components that stay in PAG solution for intended duration, and meeting component durability requirement.

36 MATERIALS SCIENCE↗