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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Urban weather modeling using WRF: linking physical assumptions, code implementation, and observational needs

The Weather Research and Forecasting (WRF) model includes urban schemes that simulate the influence of urban surfaces on the atmosphere using parameterizations for flux, and radiative exchanges. Three core schemes – the Bulk urban parameterization, Single-Layer Urban Canopy Model (SLUCM), and Multi-Layer Urban Canopy Model (MLUCM) – represent increasing levels of complexity. Although the parameterizations within these urban schemes are described in the literature, their specific implementation remains poorly documented, thus slowing down model development efforts. This manuscript provides a roadmap to the three urban schemes in WRF version 4.5.2, presenting equations using the same symbols as in the model code, along with references to code lines, and including graphics and explanations that connect the code to its physical foundations. Our thorough review of the urban parameterizations implemented in WRF version 4.5.2 highlighted a handful of parameters that may introduce discontinuities in simulations: (i) in the SLUCM, a 1 mm h −1 rain rate threshold is employed to switch between two minimum moisture availability parameterizations, thus impacting latent heat flux calculations; (ii) in the SLUCM a threshold is used to partition shortwave radiation into direct and diffuse components; (iii) in all three urban schemes, the bulk Richardson number is employed to select the similarity function, which influences the vertical distribution of heat and momentum. We also identified a highly simplified treatment of the radiative balance on roof surfaces. The implications of these simplifications can be assessed through targeted observations across relevant conditions, including varying precipitation rates, cloud cover, and transitions between stability regimes. Furthermore, the widespread application of the Monin-Obukhov similarity theory in these urban schemes warrants model evaluation under highly stable and unstable conditions and in heterogeneous urban settings with variable land cover and building heights on scales finer than model resolution. To address these challenges, we offer guidance on observational strategies, emphasizing the need for multi-parametric measurements to capture potential compensating biases and multi-height measurements that align with the levels where quantities are diagnostic and prognosed in the model (i.e., the lowest atmospheric level of the WRF model). Finally, our inspection of the code revealed implementation bugs that have now been corrected in WRF versions 4.6.0 and 4.6.1. Sensitivity tests over the Atlanta urban area show that these corrections affect surface temperatures, underscoring the importance of performing rigorous documentation and verification of the implementation of parameterizations in model code.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1975

Wind tunnel measurements in the wake of a simple structure in a simulated atmospheric flow

Measurements of longitudinal mean velocity and turbulence intensity were made in the wake of a rectangular model building in a simulated atmospheric boundary-layer wind. The model building was a 1:50 scale model of a structure used in a wake measurement program at the George C. Marshall Space Flight Center 8-tower boundary-layer facility. The approach wind profile and measurement locations were chosen to match the field site conditions. The wakes of the building in winds from azimuths of 0 and 47 degrees referenced to the normal to the building long axis were examined. The effect of two lines of trees upwind of the building on the wake and the importance of the ratio of the building height to boundary-layer thickness on the extent of the wake were determined.

Hansen, A. C.↗
NASA NTRS2023

Hot Cracking Behavior and Beam-Induced Grain Refinement in Electron Beam Freeform Fabricated Al 7075

Electron beam freeform fabrication (EBF 3 ) is a high deposition rate, wire-based directed energy deposition (DED) additive manufacturing (AM) process used to print metallic parts in a vacuum environment. While high specific strength 7xxx-series Al alloys are of interest in the aerospace and automotive industries, these alloys suffer from hot cracking issues during fusion welding and AM. In this work, linear deposits of Al 7075 were fabricated with EBF 3 to study the effects of baseplate thickness, preheat temperature, and beam focus on hot cracking behavior. Solidification cracks were observed in the first deposition layer, and by the third layer coalesced into large “macrocracks” running vertically through the build height. Fine, intergranular liquation “microcracks” appeared between macrocracks below the root of the final deposit layer fusion zone. Increasing the substrate preheat temperature from 165°C to 320°C deepened the partially melted zone and resulted in a more than twofold increase in the liquation microcrack density. Analysis of Scheil solidification diagrams revealed that fugitive losses of Zn and Mg during deposition increased the susceptibility to solidification cracking and promoted substrate liquation cracking. Focused electron beam (EB) conditions combined with a high aspect ratio elliptical raster pattern resulted in bands of refined, equiaxed grains. The refined microstructure suppressed solidification macrocracking and caused a nearly fivefold reduction in liquation crack density, demonstrating that beam-induced grain refinement may be a promising low-cost method for reducing hot cracking during AM.

aluminum↗
NASA NTRS1998

Prediction Based Design of Fire Detection for Buildings with Ceiling Heights between 9m and 18m

The purpose of this paper is to provide the experimental and theoretical background necessary to extend guidelines to ceiling heights between 9 m and 18 m. Based on the results of experiments conducted in 15 m and 22 m high hangars, detector activation thresholds and detector spacing are analyzed for both smoke and heat detectors. Only ceiling mounted detection devices are analyzed in this paper. In addition to the detector threshold study, the predictive capabilities of computer fire model simulations were compared with experimental results. This comparison, which is based on 12 fire tests, resulted in the development of a new ceiling jet algorithm to model phenomena which had not been included in previous algorithms. The improved algorithm provides a better representation of the development of the ceiling jet temperature to a growing hot layer and a better estimation of plume centerline temperature. Guidelines are examined, based on the experimental results, for fire detector spacing, placement, and sensitivity. Recommendations concerning the use of computer fire models at these heights are made as a function of fire size and hot layer development. The role of draft curtains is discussed and their impact on detector activation is demonstrated.

Davis, W. D.↗
DOE OSTI2024

Coaxial color channel focus evaluation to estimate standoff height in directed energy deposition additive manufacturing

Directed energy deposition (DED) is an additive manufacturing process that is being rapidly adopted by industry and is well suited for the fabrication of complex components in a variety of metal alloys. In laser cladding systems such as DED, powder is blown in a stream to a metal substrate coincident with a laser necessary to deposit molten metal with 3D spatial control. The focus of both the laser and the powder stream are crucial, and best deposition occurs at a predetermined standoff height between the build surface and the print head. Generally, no monitoring of this distance is implemented in commercial DED systems. Due to potential over or under building, the standoff height often changes over time but tends to self-correct. However, inexpensive and minimally intrusive methods to identify optimal standoff are required to provide real-time control to maintain the optimal distance. The present work explores the quantification of the focus of the three-color channels of a coaxial camera to determine the standoff height. An experiment was performed in which a 254 mm wall is built and the standoff height, initially 5.0 mm below the optimal position, was then intentionally increased every 25.4 mm of wall length by an amount of 1.0 mm to a final position 7.0 mm above optimal. Computer vision is demonstrated to monitor the amount of focus in each color band and estimate standoff distance. Finally, a response can be calculated in under 40 ms using simple hardware and can work in most laser-based DED systems.

36 MATERIALS SCIENCE↗
DOE OSTI2022

3D Reality Energy Modeling Software

The team will combine Bentley Systems’ ContextCapture and extend Oak Ridge National Laboratory’s building energy modeling capabilities in order to create digital twins of buildings that allow simulation-informed improvement for energy efficiency and demand response in the design and operation of the built environment. Bentley Systems’ ContextCapture software processes data from 3D laser scanning and photographs (through photogrammetry) to create a photorealistic, 3D mesh with a scale of individual objects to building to city-sized. This capability easily provides city-level visualization models and platforms where sustainable design alternatives are readily evaluated. Oak Ridge National Laboratory (ORNL) serves the U.S. Dept. of Energy (DOE) as one of three core laboratories developing building energy modeling tools EnergyPlus and OpenStudio. ORNL’s AutoBEM software (bit.ly/AutoBEM) can process imagery (satellite, aerial, and street level), LiDAR, cartographic layers, tax assessor’s data, and other data sources to extract building footprints, height, window-to-wall ratio, building type, vintage, and other building properties. AutoBEM has created 178,368 building energy models that were empirically validated with 15-minute whole-building electrical data from a utility.

97 MATHEMATICS AND COMPUTING↗
NASA NTRSDate not supplied

Investigate the height dependency of the micro-/defect-structure and mechanical properties of additively manufactured AlF357 aluminum alloy

When the laser powder bed fusion (L-PBF) additive manufacturing method is employed to build parts with increased heights, there is a possibility that defects are increased in part. This study investigates the effect of build height on the micro-/defect-structure and, consequently, the mechanical properties of L-PBF AlF357, an Al-Si-Mg alloy family. Tall vertical cylinders of 316 mm with 15 mm diameter were fabricated and cut into specimens at different heights. Although not much difference is observed in the microstructure (grain size and morphology), the defects' size and population slightly vary with height. Nonetheless, the tensile properties of the L-PBF AlF357 are found to be independent of height. This is ascribed to the approximately identical microstructure and marginal difference in the defect's size and distribution along the heights.

Laser powder bed fusion (L-PBF)↗
NASA NTRS1972

Design of toroidal transformers for maximum efficiency

The design of the most efficient toroidal transformer that can be built given the frequency, volt-ampere rating, magnetic flux density, window fill factor, and materials is described. With the above all held constant and only the dimensions of the magnetic core varied, the most efficient design occurs when the copper losses equal 60 percent of the iron losses. When this criterion is followed, efficiency is only slightly dependent on design frequency and fill factor. The ratios of inside diameter to outside diameter and height to build of the magnetic core that result in transformers of maximum efficiency are computed.

Dayton, J. A., Jr.↗
NASA NTRSDate not supplied

Corridor Design and Analysis for UAM Operations

The Urban Air Mobility (UAM) concept is a part of Advanced Air Mobility (AAM), a joint initiative between the Federal Aviation Administration (FAA), NASA, and industry to develop an air transportation system that uses new electric (i.e., green) air vehicles in geographical areas previously underserved by traditional aviation. Market forecast studies predict that there will be demand for alternate modes of air transportation using electric Vertical Take-off and Landing aircraft. UAM expands transportation networks by introducing short flights to move people and goods around metropolitan areas​. UAM is expected to improve mobility for the public, decongest road traffic, reduce trip time, and decrease strain on existing public transportation networks. Various challenges exist to make the introduction of UAM operations successful in the U.S. National Airspace System (NAS). These include but are not limited to integration with existing airports and airspace, provision of air traffic services (e.g., separation), vehicle design and certification, and community acceptance. The focus of this paper is on integration of UAM operations into the NAS via introduction of new airspace structures. UAM will operate within a regulatory, operational, and technical environment that is incorporated into the NAS​. As per the UAM Concept of Operations (ConOps), the FAA retains regulatory authority and is responsible for establishing operational parameters and maintaining oversight. The FAA’s UAM ConOps describes flights at low altitudes (below 5,000 ft) with minimal disruption to established conventional aircraft traffic and limited voice interactions with the Air Traffic Control (ATC). Early stages of UAM may use existing procedures to safely integrate UAM with conventional flights. This would involve flying under Part 91 Visual Flight Rules (VFR) and using voice for communications. The initial UAM ecosystem will utilize the current infrastructure such as routes, helipads, and ATC services, where practicable. ​A NASA study explored the use of existing helicopter routes in Dallas Fort Worth (DFW) airspace for initial UAM operations with a Letter of Agreement (LOA) that included procedures to request a Class B (controlled airspace) clearance. The research showed that the chosen approach was feasible for near-term, low-demand UAM traffic, but was not scalable. The growth of operations in today’s aviation system has resulted in airspace reorganization and procedures to ensure safety and efficiency as traffic rates increase. One proposed operating innovation that can help with the scalability of UAM is establishing routes and corridors. This may look similar to the Area Navigation (RNAV) procedures used today to streamline operations into busy airports. However, instead of FAA automation systems and ATC managing the flow of traffic, some UAM concepts envision a third-party service provider performing this role as part of the Provider of Services for UAM (PSU) network. The FAA’s UAM ConOps posits that new airspace structures such as UAM corridors include the following design criteria: 1) Minimal impact on existing NAS operations, 2) no or minimal additional ATC services, 3) public interest considerations such as noise, safety, and security, and 4) customer needs. The airspace available in urban environments is limited by the height of buildings, the effect of weather including wind gusts, privacy needs, and a clearance envelope. The new airspace structure would need to be designed around large airports and urban areas where the initial market demand is likely to exist. NASA has started evaluating airspace in the Dallas Fort Worth area to design new airspace structures, keeping the first two design criteria in mind. It is assumed that there will be an on-board pilot-in-command, and the flights will operate under VFR in Visual Meteorological Conditions. Corridors will be required in controlled airspace, whereas UAM operations can fly in uncontrolled Class G and E airspace using current day rules. Keeler et. al identified factors and heuristics for development of routes for UAM operations for integration with airspace close to large airports such as Dallas Fort Worth and Dallas Love Field. This paper describes the heuristics applied to define the corridors, analyzes them with respect to legacy traffic and presents key results.

Urban Air Mobility↗
DOE OSTI2022

NATURF

The Neighborhood Adaptive Tissues for Urban Resilience Futures tool (NATURF) is a Python workflow that generates les readable by the Weather Research and Forecasting (WRF) model. The NATURF Python modules use shapefiles containing building footprint and height data as input to calculate 132 building parameters at any resolution and converts the parameters into a binary file format.

Allen-Dumas, MelissaRee [Oak Ridge National Lab. (↗
NASA NTRSDate not supplied

Capacity Building Engagement for Estimating Forest Stand Height Utilizing the SAR Handbook

Utilizing Synthetic Aperture Radar (SAR) which provides information such as vegetation structure and moisture content, independently of weather conditions is a powerful tool that can be employed to more effectively monitor deforestation and estimate biomass which is of paramount concern, especially in South and Southeast Asia which contain nearly 15% of all tropical forests. SERVIR, a NASA-USAID initiative, works in partnership with regional hubs around the world building capacity through promoting the use of Earth observations and geospatial technologies. The SERVIR Global network and the Silva Carbon program collaboratively developed the SAR Handbook: Comprehensive Methodologies for Forest Monitoring and Biomass Estimation which set out to reduce the barriers associated with leveraging SAR and increase the capacity of researchers and practitioners globally to use SAR for monitoring. In particular, utilizing SAR to estimate Forest Stand Height (FSH) is crucial for greenhouse gas emissions reporting and estimating carbon storage. Programs such as Reducing Emissions from Deforestation and Forest Degradation (REDD) rely on parameters such as these for their monitoring efforts. This talk will showcase the collaborative efforts, emergent geospatial technology leveraged, and capacity building approaches utilized by our team to conduct a South and Southeast Asia focused in-person training event located at SERVIR-Mekong, a SERVIR hub lead by the Asian Disaster Preparedness Center (ADPC) in Bangkok.

AGU↗
DOE OSTI2025

A machine learning method of modern urban building energy modeling: A case study of Chicago

Urban-scale building energy modeling is vital for urban planning. However, it can be challenging to assimilate reliable non-geometry building data for urban-scale modeling without extensive investment. Here, this study introduces a novel approach to developing modern urban-scale building energy stock data using geographic information systems and machine learning algorithms without necessarily requiring pre-supplied non-geometric metadata. The proposed framework integrates building footprint and height data to estimate gross floor areas, and matches each building to a pool of candidate records from ComStock or ResStock—filtered to the same county and ranked by geometric similarity—demonstrate a proof-of-concept case study in Chicago for predicting energy use intensity (EUI) using scalable datasets. The model achieved a mean bias error (MBE) of 0.08 kWh/m² and root mean square error (RMSE) of 14.84 kWh/m² under full metadata input for EUI prediction. With only location inputs, the model captured 69.2 % of EUI within predicted ranges. These results demonstrate the model’s potential to support early-stage urban planning, identify candidates for energy-efficient retrofits. By removing the dependency on detailed pre-surveys or extensive building metadata, the approach overcomes a key barrier in traditional urban-scale building energy modeling, illustrating a pathway toward broader and more cost-effective application, though further multi-city validation and improved treatment of pre-1925 buildings are needed.

Energy Use Intensity↗
DOE OSTI2020

Vertical meteorological patterns and their impact on the energy demand of tall buildings

In accordance with the developing economy and growing population, an increasing number of tall buildings have been constructed over the last 20 years. In 2017, there were 144 new buildings worldwide that were 200 m or greater in height; 50% of these buildings were in China. Due to the vertical gradient impact of meteorological parameters, the energy performance of tall buildings differs from that of general buildings. Few studies exist on vertical meteorological changes using measured data at different heights. Most studies on dynamic energy simulation simulate meteorological parameters using models. This study explores vertical meteorological patterns using hourly dry-bulb temperature, relative humidity, and wind speed data from 2007 to 2017 for a 325 m meteorological tower in Beijing. The temperature decreased significantly with increasing altitude (~0.9 °C per 100 m), while the daily temperature difference decreased with increasing altitude. The absolute humidity did not change significantly with height. The wind speed increased with altitude at approximately 2 m/s per 100 m. The building simulation showed that the annual heating load at a height of 320 m increased by 85% from that at 8 m; the annual cooling load decreased by 20%. Such significant differences in thermal loads for 300-m-tall buildings confirm the need to consider vertical meteorological differences in building performance simulations for tall buildings. A greater number of measurement points at different heights improve the simulation accuracy. Finally, guidance on selecting the heights for vertical metrological measurements is provided based on the influences of building thermal loads.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1989

Comparison of analytical methods for calculation of wind loads

The following analysis is a comparison of analytical methods for calculation of wind load pressures. The analytical methods specified in ASCE Paper No. 3269, ANSI A58.1-1982, the Standard Building Code, and the Uniform Building Code were analyzed using various hurricane speeds to determine the differences in the calculated results. The winds used for the analysis ranged from 100 mph to 125 mph and applied inland from the shoreline of a large open body of water (i.e., an enormous lake or the ocean) a distance of 1500 feet or ten times the height of the building or structure considered. For a building or structure less than or equal to 250 feet in height acted upon by a wind greater than or equal to 115 mph, it was determined that the method specified in ANSI A58.1-1982 calculates a larger wind load pressure than the other methods. For a building or structure between 250 feet and 500 feet tall acted upon by a wind rangind from 100 mph to 110 mph, there is no clear choice of which method to use; for these cases, factors that must be considered are the steady-state or peak wind velocity, the geographic location, the distance from a large open body of water, and the expected design life and its risk factor.

Minderman, Donald J.↗
DOE OSTI2024

naturf: a package for generating urban parameters for numerical weather modeling

The Neighborhood Adaptive Tissues for Urban Resilience Futures tool (NATURF) is a Python workflow that generates files readable by the Weather Research and Forecasting (WRF) model. NATURF uses geopandas and hamilton to calculate 132 building parameters from shapefiles with building footprint and height information. These parameters can be collected and used in many formats, and the primary output is a binary file configured for input to WRF. This workflow is a flexible adaptation of the National/World Urban Database and Access Portal Tool (NUDAPT/WUDAPT) that can be used with any study area at any spatial resolution. The climate modeling community and urban planners can identify the effects of building/neighborhood morphology on the microclimate using the urban parameters and WRF-readable files produced by NATURF. More information on the urban parameters calculated can be found in the documentation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Building morphologies of the USA structures database; a gauntlet feature set

In recent years there has been a proliferation of methods and data to extract building footprints from satellite imagery. However there has been very little effort to provide additional insight about these buildings beyond their spatial location and shape. Features derived from their geometries can be used to better characterize these buildings which are critical for further research and development. In this work a set of 65 unique features for every building for more than 131 million buildings covering the US has been developed. This rich feature dataset will enable researchers, policymakers and various agencies to derive additional building characteristics like height, occupancy type, and help to gain valuable and new insights of the built environment.

Environmental sciences↗