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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 541 records · Page 30

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NASA NTRS1978

The practical impact of elastohydrodynamic lubrication

Elastohydrodynamic lubrication has had its most significant impact on, among all the types of concentrated contact mechanisms, rolling element bearings. EHL technology, through its inclusion in computer codes, now provides us with more effective methods for optimizing bearing design and for predicting bearing life, power loss, temperature and dynamic behavior. Bearing life prediction has advanced to a much more sophisticated level as compared to the calculation of fatigue life based on Lundberg-Palmgren theory. Application of elastohydrodynamics to gearing has, more or less, been limited to the calculation of pitch point film thicknesses. Techniques for calculating film thicknesses over the entire range of tooth meshes for arbitrarily shaped gear teeth (noninvolute, spur, helical, etc.) need to be developed. Elastomer seals with both unidirectional and reciprocating motion offer a fruitful application for the elastohydrodynamics of low modulus materials.

Anderson, W. J.↗

NASA NTRS1986

Behavior of a non-wetting melt in free fall - Theoretical

In a previous paper the experimental equilibrium configurations of a nonwetting liquid in an ampoule were described. Theoretical analyses of these configurations are described here. In a cylindrical ampoule a bubble/bridge configuration is predicted to be stable only up to a critical volume of gas, beyond which separated columns of liquid form. This critical bubble volume decreases as the contact angle of the liquid on the ampoule increases. In a triangular ampoule the liquid contacts the ampoule along the center of the faces and not in the corners. As the contact angle increases beyond 90 deg, the contact width decreases.

Sen, Radha↗

NASA NTRS2000

Lunar Dust Contamination Effects on Lunar Base Thermal Control Systems

Many studies have been conducted to develop a thermal control system that can operate under the extreme thermal environments found on the lunar surface. While these proposed heat rejection systems use different methods to reject heat, each system contains a similar component, a thermal radiator system. These studies have always considered pristine thermal control system components and have overlooked the possible deleterious effects of lunar dust contamination. Since lunar dust has a high emissivity and absorptivity (greater than 0.9) and is opaque, dust accumulation on a surface should radically alter its optical properties and therefore alter its thermal response compared to ideal conditions. In addition, the non-specular nature of the dust particles will alter the performance of systems that employ specular surfaces to enhance heat rejection. To date, few studies have examined the effect of dust deposition on the normal control system components. These studies only focused on a single heat rejection or photovoltaic system. These studies did show that lunar dust accumulations alter the optical properties of any lunar base hardware, which in turn affects component temperatures, and heat rejection. Therefore, a new study was conducted to determine the effect of lunar dust contamination on heat rejection systems. For this study, a previously developed dust deposition model was incorporated into the Thermal Synthesizer System (TSS) model. This modeling scheme incorporates the original method of predicting dust accumulation due to vehicle landings by assuming that the thin dust layer can be treated as a semitransparent surface slightly above and in thermal contact with the pristine surface. The results of this study showed that even small amounts of dust deposits can radically alter the performance of the heat rejection systems. Furthermore. this study indicates that heat rejection systems be either located far from any landing sites or be protected from dust producing mechanisms.

Keller, John R.↗

NASA NTRS2011

Which Way is Up? Lessons Learned from Space Shuttle Sensorimotor Research

The Space Shuttle Program provided the opportunity to examine sensorimotor adaptation to space flight in unprecedented numbers of astronauts, including many over multiple missions. Space motion sickness (SMS) severity was highly variable across crewmembers. SMS generally lasted 2-3 days in-flight with approximately 1/3 of crewmembers experiencing moderate to severe symptoms, and decreased incidence in repeat flyers. While SMS has proven difficult to predict from susceptibility to terrestrial analogs, symptoms were alleviated by medications, restriction of early activities, maintaining familiar orientation with respect to the visual environment and maintaining contact cues. Adaptive changes were also reflected by the oculomotor and perceptual disturbances experienced early inflight and by the perceptual and motor coordination problems experienced during re-entry and landing. According to crew self-reports, systematic head movements performed during reentry, as long as paced within one's threshold for motion tolerance, facilitated the early readaptation process. The Shuttle provided early postflight crew access to document the initial performance decrements and time course of recovery. These early postflight measurements were critical to inform the program of risks associated with extending the duration of Shuttle missions. Neurological postflight deficits were documented using a standardized subjective rating by flight surgeons. Computerized dynamic posturography was also implemented as a quantitative means of assessing sensorimotor function to support crew return-to-duty assessments. Towards the end of the Shuttle Program, more emphasis has been placed on mapping physiological changes to functional performance. Future commercial flights will benefit from pre-mission training including exposures to launch and entry G transitions and sensorimotor adaptability assessments. While SMS medication usage will continue to be refined, non-pharmacological countermeasures (e.g., sensory aids) will have both space and Earth-based applications. Early postflight field tests are recommended to provide the evidence base for best practices for future commercial flight programs. Learning Objective: Overview of the Space Shuttle Program regarding adaptive changes in sensorimotor function, including what was learned from research, what was implemented for medical operations, and what is recommended for commercial flights.

Wood, S. J.↗

DOE OSTI2023

A constitutive model for sheared dense fiber suspensions

Here we propose a constitutive model to predict the viscosity of fiber suspensions, which undergoes shear thinning, at various volume fractions, aspect ratios, and shear stresses/rates. We calibrate the model using the data from direct numerical simulation and prove the accuracy by predicting experimental measurements from the literature. We use a friction coefficient decreasing with the normal load between the fibers to quantitatively reproduce the experimentally observed shear thinning in fiber suspensions. In this model, the effective normal contact force, which is directly proportional to the bulk shear stress, determines the effective friction coefficient. A rise in the shear stress reduces the effective friction coefficient in the suspension. As a result, the jamming volume fraction increases with the shear stress, resulting in a shear thinning in the suspension viscosity. Moreover, we extend the model to quantify the effects of fiber volume fraction and aspect ratio in the suspension. We calibrate this model using the data from numerical simulations for the rate-controlled shear flow. Once calibrated, we show that the model can be used to predict the relative viscosity for different volume fractions, shear stresses, and aspect ratios. The model predictions are in excellent agreement with the available experimental measurements from the literature. The findings of this study can potentially be used to tune the fiber size and volume fraction for designing the suspension rheology in various applications.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1977

Fluidized bed combustor modeling

A general mathematical model for the prediction of performance of a fluidized bed coal combustor (FBC) is developed. The basic elements of the model consist of: (1) hydrodynamics of gas and solids in the combustor; (2) description of gas and solids contacting pattern; (3) kinetics of combustion; and (4) absorption of SO2 by limestone in the bed. The model is capable of calculating the combustion efficiency, axial bed temperature profile, carbon hold-up in the bed, oxygen and SO2 concentrations in the bubble and emulsion phases, sulfur retention efficiency and particulate carry over by elutriation. The effects of bed geometry, excess air, location of heat transfer coils in the bed, calcium to sulfur ratio in the feeds, etc. are examined. The calculated results are compared with experimental data. Agreement between the calculated results and the observed data are satisfactory in most cases. Recommendations to enhance the accuracy of prediction of the model are suggested.

Horio, M.↗

DOE OSTI2024

Evaporation from thin porous Coatings: Pore size effects and predictive equation for homogeneous coatings

Evaporation of small water droplets on solids is hindered because surface tension pulls the droplet into a spherical cap that has a small perimeter. Our solution is to coat a solid with a very thin, porous layer into which the droplet flows to create a large-area disk with concomitant high rate of evaporation. We investigate evaporation by varying factors that have not been previously considered: pore size and distribution, contact angle, temperature, and relative humidity (RH). A larger pore size resulted in faster evaporation, which we explain through faster transport within the coating. Even faster evaporation occurred for a bilayer structure with small particles on the air side and larger particles on the solid side. Further, the water advancing contact angle had an insignificant effect in the range from < 10° through to 60°. Our results for different pore sizes, temperature, humidity, and contact angle all collapse onto a single curve when appropriately normalized. This validates an equation that can be used for the evaporation from a homogeneous coating that depends only one empirical factor and the droplet volume. Since the volume is often user-controlled, we envisage that this equation can be used to predict evaporation and guide design of fast-drying coatings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Modelling the limiter ramp-up of WEST for addressing the future challenges of ITER

This paper presents a joint experimental and numerical investigation into the physics of long limited plasma ramp-up in tokamaks with tungsten (W) first walls, a critical phase for ITER operation. The comparison between the average plasma quantities simulated using the SolEdge-HDG code and the measurements taken during three successive WEST discharges after boronisation shows how challenging it is to predict this phase. While simulations reproduce the general trends at the midplane, with reasonable match in density profiles, they consistently underestimate core temperatures possibly due to too large perpendicular heat conductivity. On the contrary, at the high field side (HFS) limiter, simulations overestimate the measured quantities, and highlights the limitation of using Bohm boundary conditions at grazing magnetic angles. Experimental measurements reveal that the boron layer is rapidly eroded, on a timescale comparable to a single ITER discharge. The subsequent transition from a boron-coated to a tungsten wall increases recycling and significantly degrades the core plasma, reducing the electron temperature by nearly half due to W contamination, despite wall parameters remaining stable. Furthermore, comparisons with Langmuir probes, bolometry, reflectometry, and spectroscopy indicate that the experimental far scrape-Off layer (SOL) is significantly wider than simulated. This wide SOL implies that boron erosion extends along the entire HFS limiter rather than being confined to the contact point. This work highlights some characteristics of the plasma during this phase of the discharge and emphasizes the current modelling issues that need to be resolved in order to obtain reliable predictions concerning the ITER ramp-up.

ITER↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Discrete Element Method↗

DOE OSTI2025

The molten salt tritium transport experiment: A pumped fluoride salt loop for hydrogen isotope experimentation

Molten salt reactors (MSRs) and fusion reactors propose to use molten salts as coolants and breeder blanket materials, respectively. Tritium, however, poses safety concerns in both reactor types due to its ability to permeate through reactor materials and potential for environmental release. This manuscript addresses the tritium transport phenomena in molten salts and presents the design and analysis of the Molten Salt Tritium Transport Experiment (MSTTE). MSTTE is a forced-convection fluoride salt loop intended to measure hydrogen isotope permeation through structural materials in a flowing salt system. In the first phase, MSTTE will use FLiNaK salt and deuterium as surrogates for FLiBe and tritium, with future plans to utilize tritium and FLiBe. MSTTE couples a Copenhagen Atomics pumped salt loop with an external test section that introduces hydrogen isotopes into the loop and measures transport phenomena. The Hydrogen Injection System (HIS) controls hydrogen isotope introduction into the molten salt loop. Here, the permeation test section measures the permeation rate through stainless steel tubing in contact with flowing salt. Computational fluid dynamics (CFD) analysis ensures fully developed salt flow in the permeation test section. MSTTE is modeled with MELCOR-TMAP to predict the permeation rate as a function of experimental variables such as source term, salt flow rate, and salt temperature. Results indicate that the source term is the only parameter with a significant effect on the permeation rate. Pressure drop analysis suggests that the loop should operate below 200 LPM to maintain a pressure drop below 200 kPa. Additionally, finite-element analysis assesses thermal stress during loop operation to ensure the experiment's safe design. MSTTE will provide semi-integral data on tritium transport phenomena in molten salts and serve as a testbed for advancing molten salt technology.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Modeling the hydrodynamic impact on the tool influence function during hemispherical subaperture optical polishing

To fabricate high-precision and accurate optics relative to the optical design surface, a high level of deterministic control of material removal (i.e., the tool influence function, TIF) during subaperture tool polishing is required. In this study, a detailed analysis of the pressure distribution, which is a key component of the TIF, has been performed using finite element analysis to couple together solid mechanics and fluid dynamics. Modeling experimental parameters of recently published work reveals that, when considering tool deformation, which in turn influences the fluid film thickness between the tool and workpiece, the effective pressure profile has a flat-top distribution. This flat-top pressure profile differs from the parabolic pressure distributions predicted by Hertzian mechanics. Furthermore, the shear contribution is shown here to be a key contributor to material removal, inducing the removal at the periphery of the contact edge and even outside the generally accepted contact area. Finally, the simulated fluid velocities provide evidence of mixed-mode contact polishing, supporting recent experimental findings that also suggest that onset of hydroplaning contributions lead to material removal drop-off.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Constrained fatigue life optimization of a NASVYTIS multiroller traction drive

A contact fatigue life analysis method for multiroller traction drives is presented. The method is based on the Lundberg-Palmgren analysis method for rolling element bearing life prediction, and also uses life adjustment factors for materials, processing, lubrication, and effect of traction. The analysis method is applied in an optimization study to the multiroller traction drive, consisting of a single-stage planetary configuration with two rows of stepped planet rollers of five rollers per row. The drive was approximately 25 centimeters in diameter by 11 centimeters long, having a nominal ratio of 15:1. The theoretically predicted drive life was 2510 hours at a nominal continuous power and speed of 74.6 kW (100 hp) and 75,000 rpm.

Coy, J. J.↗

DOE OSTI2024

Discrete-Element and Material-Point Method (DEM and MPM) Based Solvers for Sustainable Technologies

We present the use of discrete element method (DEM) and material point method (MPM) in three relevant green technology applications that include biomass feedstock handling, lithium-ion battery manufacturing, and high-pressure reverse osmosis. Our open-source DEM and MPM solvers are developed using performance portable grid and particle management library, AMReX, thus enabling superior performance on NVIDIA and AMD GPUs with > 100 million particles. Our DEM solver resolves the motion of individual particles in a granular system and includes a bonded sphere method for modeling non-spherical particles along with Hertzian and liquid bridge-based contact models. We simulate highly variable biomass feedstock flows in large-scale hoppers for biofuel production and electrode calendering in battery manufacturing using DEM. Our simulations predict flow blockage in large scale biomass hoppers and electrode microstructure variations, thus providing valuable information for biofuel and battery manufacturers, respectively. The second half of the talk will be on MPM and its application towards pore resolved simulations of reverse osmosis membranes under compressive loads. We present a validation study of our MPM simulations with membrane microscopy imaging thus providing useful insights on membrane stability under high pressure conditions. We also present a spectral stability analysis of using linear hat, quadratic and cubic spline basis in MPM indicating regions of numerical stability.

BIOMASS FUELS,MATHEMATICS AND COMPUTING↗

DOE OSTI2022

LEAKAGE CHARACTERISTICS OF A STEPPED BALANCE PISTON LABYRINTH SEAL IN SUPERCRITICAL CO2

In an integrally geared compressor, there is a net thrust load on the pinion shaft from gear loads and aerodynamic forces. The net thrust on the pinion is resolved with either a thrust bearing or a thrust collar (rider ring). As the pressure increases, this increases the aerodynamic force proportionally. In highpressure systems this can overwhelm the thrust bearing or thrust collar if thrust is mismanaged. In a recent test program for an sCO2 integrally geared compander (compressor/turbine), a balance piston was created on the opposite end of the turbine to provide an equalizing thrust; while this is not novel, the balance piston provided a test apparatus for measuring the leakage on a 20 tooth stepped labyrinth seal operating at pressures in excess of 250 bar (3600 psi). The stepped balance piston seal is a 20 tooth tooth-onrotor balance piston seal. This type of seal was selected since it was predicted to have substantially less leakage than a comparably sized straight through labyrinth seal. Comparisons between the two designs will be made, showing that the leakage of the stepped balance piston seal is considerably lower. The tooth clearance on the seal was selected to be 30 mils radial. While this seems large, a stack-up tolerance assessment showed that this magnitude of clearance was appropriate to prevent rotor stator contact. During the testing campaign, data was recorded showing the leakage across this stepped balance piston seal at pressures in excess of 250 bar (3600 psi) with a pressure ratio of 2. This leakage data was measured, and will be compared to leakage data predicted with CFD. Two measurement methods are presented for the stepped balance piston seal: an orifice plate and valve. The predicted seal leakage from a straight through seal was four times that of the predicted stepped labyrinth seal. The measured flow from the stepped seal was on the same order as the CFD prediction and offered adequate rotordynamic performance

wilkes, jason↗

DOE OSTI2022

Enhancing high-fidelity nonlinear solver with reduced order model

Abstract We propose the use of reduced order modeling (ROM) to reduce the computational cost and improve the convergence rate of nonlinear solvers of full order models (FOM) for solving partial differential equations. In this study, a novel ROM-assisted approach is developed to improve the computational efficiency of FOM nonlinear solvers by using ROM’s prediction as an initial guess. We hypothesize that the nonlinear solver will take fewer steps to the converged solutions with an initial guess that is closer to the real solutions. To evaluate our approach, four physical problems with varying degrees of nonlinearity in flow and mechanics have been tested: Richards’ equation of water flow in heterogeneous porous media, a contact problem in a hyperelastic material, two-phase flow in layered porous media, and fracture propagation in a homogeneous material. Overall, our approach maintains the FOM’s accuracy while speeding up nonlinear solver by 18–73% (through suitable ROM-assisted FOMs). More importantly, the proximity of ROM’s prediction to the solution space leads to the improved convergence of FOMs that would have otherwise diverged with default initial guesses. We demonstrate that the ROM’s accuracy can impact the computational efficiency with more accurate ROM solutions, resulting in a better cost reduction. We also illustrate that this approach could be used in many FOM discretizations (e.g., finite volume, finite element, or a combination of those). Since our ROMs are data-driven and non-intrusive, the proposed procedure can easily lend itself to any nonlinear physics-based problem.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Separation of volatile organic contaminants from water using a direct-contact dehumidifier: An experimental study and modeling

A packed-bed, direct-contact dehumidifier (PB-DCD) has been developed to selectively condense water from a gaseous mixture of organic contaminants. In this process, hot air is humidified by mixing with wastewater vapor in a static mixer and is dehumidified by subcooled fresh water passing through the PB-DCD in a counter-current configuration. The goal of this study is to understand the relationship between various operating parameters and how they affect separation of isopropyl alcohol (IPA) from the gaseous mixture with the purpose of expanding the investigation to other contaminants in the future. The process has been successfully used to separate IPA from wastewater. Different parameters including the concentration of IPA in water, feed temperature, air-to-vapor ratio, and cooling-water-to-vapor mass ratio, as well as residence time were examined to determine their influence on contaminant separation and clean water recovery rate. The Buckingham Pi theorem was applied to reduce the number of studying variables by generating non-dimensional groups. Experiments were performed to determine the relationship between the non-dimensional parameters and model mass transfer in the system. Mass transfer coefficients for multicomponent gaseous mixture condensation in a packed-bed direct contact condenser column are calculated and a modified correlation of mass transfer is developed. The parameters of the mass transfer model are obtained from operating conditions of the PB-DCD, stream conditions and thermodynamic properties. A modified Sherwood correlation is developed to predict IPA separation from a gaseous mixture consisting of air, water, and IPA. The modified Sherwood correlation is applied to successfully predict the Sherwood number with a mean absolute error equal to 6.6 %. According to the experimental results, the maximum IPA separation achieved was 76.3 %, which corresponds to a water recovery rate of 58.7 %.

42 ENGINEERING↗

DOE OSTI2026

Prediction and Experimental Verification of Electrolyte Solvation Structure from an OMol25-Trained Interatomic Potential

A molecular-level understanding of electrolyte solvation structure and ion–ion correlations is critical to developing next-generation battery chemistries. Atomistic simulation capabilities with sufficient accuracy, speed, and transferability to deliver reliable structural insights while avoiding arduous system-specific reparameterization are thus highly desirable. Machine learning interatomic potentials (MLIPs) trained on large, chemically diverse data sets are revolutionizing computational chemistry, enabling molecular dynamics simulations of battery electrolytes with near-DFT accuracy over 10,000× faster than DFT. While previous MLIP training data sets with suitable elemental coverage for electrolytes have been based on inorganic materials, the Open Molecules 2025 (OMol25) data set provides large-scale molecular DFT MLIP training data with broad elemental coverage and specifically samples tens of millions of electrolyte configurations. Here, we integrate computational modeling with experimental validation to systematically assess the ability of large-scale MLIPs pretrained on materials data or on OMol25 to accurately resolve nanoscale structural organization and ion-solvation characteristics in Na-ion battery electrolytes across diverse physicochemical conditions and compositional regimes. We find that the OMol25-trained Universal Model of Atoms (UMA-OMol) predicts experimentally measured densities and X-ray structure factors in substantially better agreement compared to state-of-the-art models trained only on inorganic materials data. Using UMA-OMol, we further analyze systematic trends in solvation structure as a function of cation identity, anion chemistry, salt concentration, and solvent topology. We observe that increasing system temperature amplifies the heterogeneity within the solvation environment, perturbing cation–solvent interactions and promoting the formation of contact ion pairs (CIPs). Moreover, subtle variations in the solvent topology of glyme-based electrolytes cause pronounced changes in ion correlations and solvation structure. The experimental agreement and microscopic insights shown here position OMol25-trained MLIPs as a practical route to predictive, high-throughput electrolyte simulations beyond the limits of classical force fields and direct DFT molecular dynamics, serving as a powerful tool for accelerating the design of next-generation Na-ion battery electrolytes and beyond.

MLIPs↗