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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 649 records · Page 36

A Software Upgrade of the NASA Aeroheating Code "MINIVER"

Computational Fluid Dynamics (CFD) is a powerful and versatile tool simulating fluid and thermal environments of launch and re-entry vehicles alike. Where it excels in power and accuracy, however, it lacks in speed. An alternative tool for this purpose is known as MINIVER, an aeroheating code widely used by NASA and within the aerospace industry. Capable of providing swift, reasonably accurate approximations of the fluid and thermal environment of launch vehicles, MINIVER is used where time is of the essence and accuracy need not be exact. However, MINIVER is an old, aging tool: running on a user-unfriendly, legacy command-line interface, it is difficult for it to keep pace with more modem software tools. Florida Institute of Technology was tasked with the construction of a new Graphical User Interface (GUI) that implemented the legacy version's capabilities and enhanced them with new tools and utilities. This thesis provides background to the legacy version of the program, the progression and final version of a modem user interface, and benchmarks to demonstrate its usefulness.

Louderback, Pierce Mathew↗

Ultrasonic NDE Simulation for Composite Manufacturing Defects

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

Leckey, Cara A. C.↗

Progress Toward Evaluating Roughness-Resolved Aerothermodynamic Simulations for the Mars Sample Return Earth Entry System

This work pursues the efficient Navier-Stokes simulation, using NASA’s standard LAURA and DPLR simulation tools, of the flowfield and convective heating resulting from the patterned-roughness surface of the Mars Sample Return (MSR) Earth Entry System (EES). This type of simulation has been infeasible for past NASA missions. However, for EES, the combination of a patterned roughness heatshield approximated with a sinusoidal pattern, the zero degrees angle of attack nominal flow, and the supersonic boundary layer edge Mach number, all combine to make these roughness resolved grid simulations feasible. The patterned roughness and zero degrees angle of attack nominal flow allow the simulation domain to be reduced to a thin axial flowfield slice that captures a minimum of single period of the roughness pattern. With a periodic boundary condition applied along the boundaries of this slice, simulation on the reduced domain is identical to the full domain but with significant cost saving. The supersonic boundary layer edge Mach number prevents the upstream influence, which allows the smooth stagnation region to be frozen. This freezing of the stagnation region flow is required because of the numerical instability resulting from the tight spacing of the grid in the axial direction as the stagnation point is approached. Applying the developed analysis approach to a peak heating EES case results in a roughness augmentation factor for the convective heating of 1.32, which agrees well with correlations that predict values between 1.30 and 1.37. Analysis approach developed in this work provides the framework for future studies of turbulence modeling impacts and the influence of an ablating surface.

Earth Entry System↗

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗

Modeling the direct sun component in buildings using matrix algebraic approaches: Methods and validation

Simulation tools that enable annual energy performance analysis of optically-complex fenestration systems have been widely adopted by the building industry for use in building design, code development, and the development of rating and certification programs for commercially-available shading and daylighting products. The tools rely on a three-phase matrix operation to compute solar heat gains, using as input low-resolution bidirectional scattering distribution function (BSDF) data (10–15° angular resolution; BSDF data define the angle-dependent behavior of light-scattering materials and systems). Measurement standards and product libraries for BSDF data are undergoing development to support solar heat gain calculations. Simulation of other metrics such as discomfort glare, annual solar exposure, and potentially thermal discomfort, however, require algorithms and BSDF input data that more accurately model the spatial distribution of transmitted and reflected irradiance or illuminance from the sun (0.5° resolution). This study describes such algorithms and input data, then validates the tools (i.e., an interpolation tool for measured BSDF data and the five-phase method) through comparisons with ray-tracing simulations and field monitored data from a full-scale testbed. Simulations of daylight-redirecting films, a micro-louvered screen, and venetian blinds using variable resolution, tensor tree BSDF input data derived from interpolated scanning goniophotometer measurements were shown to agree with field monitored data to within 20% for greater than 75% of the measurement period for illuminance-based performance parameters. The three-phase method delivered significantly less accurate results. We discuss the ramifications of these findings on industry and provide recommendations to increase end user awareness of the current limitations of existing software tools and BSDF product libraries.

14 SOLAR ENERGY↗

Lattice Design and Advanced Modeling to Guide the Design of High-Performance Lightweight Structural Materials

Lightweight structural materials are required to increase the mobility of fission batteries. The materials must feature a robust combination of mechanical properties to demonstrate structural resilience. The primary objective of this project is to produce lightweight structural materials whose strength-to-weight ratios exceed those of the current widely used structural materials such as 316L stainless steels (316L SS). To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structures models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The preliminary results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison with the solid material and that the unit cell size of the lattice had a minimal effect. The novelty here is to apply up-front modeling to determine the best structure for the application before actually producing the sample. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for material development.

36 MATERIALS SCIENCE↗

Development and Use of the SPACE Computer Code for Analyzing the Space Station Electrical Power System

This special publication tells the story of the dedicated efforts of very talented individuals to create a preeminent space electrical power system modeling and simulation tool called SPACE, short for System Power Analysis for Capability Evaluation. This computer model has evolved for 30 years, withstanding the test of time and obsolescence, and garnering international recognition for its ability to simulate complex space electrical power systems. The analytical results from this model have saved millions of dollars in hardware redesign, testing, and verification for NASA's International Space Station (ISS) and its European and Russian partners. SPACE has played a pivotal role in the station's design and development and continues to support its ongoing operation. It has also extended its reach beyond the ISS to other key NASA programs, where it guides the design and planned operation of NASA's Multi-Purpose Crew Vehicle Orion and simulates electric power system operation in a dusty atmosphere on Mars' surface. The SPACE lineage was created by a core civil servant staff, supplemented by a cadre of interns and other temporary helpers. They created a tightly integrated tool that includes all phenomena that impact a solar array and battery space power system performance. SPACE is self-contained, requiring no other software modules and associated license fees. SPACE "rings true" in that is has been extensively validated with ISS on-orbit telemetry data. This report is being released as the generation of engineers who created it are nearing retirement, passing the baton to a new generation. This next generation will carry the code into the future, no doubt further evolving it to be able to assure mission planners that newly conceived systems will successfully power NASA's next endeavors. As a previous SPACE code developer and analyst, I have worked alongside many of the people mentioned in this report. The engineers who created the code, along with those just now learning it, are among the best and brightest at NASA. It is an honor to write this foreword as the present Branch Chief under which the legacy of SPACE continues to thrive.

Electrical Power System↗

Thermal Hydraulic Modeling of an Advanced Nuclear Reactor using open-source MOOSE tools

The aim of this study is to develop model of a small High Temperature Gas cooled Reactor (HTGR) including the balance of plant. This microreactor produces electricity using the thermal power of the nuclear reaction. This work utilizes the MOOSE Multiphysics simulation tools, which are mainly developed at Idaho National Laboratory (INL, Idaho, United States of America). Its thermal-hydraulics and Heat conduction Modules are used to study the fluids behavior in the primary loop and power conversion system and their interactions with the heating structures. More specifically, one verifies that the temperatures, pressures and mass flow rates of the fluids in both loops are consistent and that, at the same time, all the power transfers occur as expected. Moreover, the various mechanical components characteristics (turbine, compressor, pump) are adapted to the reactor operating conditions. This first analysis is conducted using simplified and one-dimensional model for the core. Ultimately, the obtained results are used to build a higher fidelity core model. This step aims to verify that the initial simplified simulation is consistent with the three-dimensional core modeling. In addition, the calculated material temperatures are checked. This study provides a fairly complete model of the thermal hydraulic phenomena for a particular design of High Temperature Gas cooled Reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

MCP-enabled agentic AI workflow for building energy modelling: framework and use cases

Traditional building energy modelling workflows remain labor-intensive and error-prone, requiring specialized expertise that limits broader adoption. This paper introduces a novel Model Context Protocol (MCP)-enabled framework that connects AI assistants to EnergyPlus through MCP, a standardized interface for tool invocation and context management. Two complementary integration paradigms are presented and compared: conversational integration, where users interact through natural language while an AI assistant orchestrates MCP tools on demand, and agentic workflow integration, where specialized agents coordinate autonomously to complete multi-step tasks. Using an experimental testbed for residential buildings, the end-to-end workflows are demonstrated. The conversational approach reduced typical inspection and modification tasks from 1-2 h to under 15 min, while maintaining full transparency through visible tool invocations. The agentic approach automated parametric analysis. These demonstrations establish MCP as a foundational layer for AI-assisted building energy modelling, enabling natural language interactions with simulation tools while preserving professional oversight and decision-making authority.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A Robust Machine Learning Schema for Developing, Maintaining, and Disseminating Machine Learning Models

Recent advances in the development of machine learning (ML) algorithms have enabled the creation of predictive models that can improve decision making, decrease computational cost, and improve efficiency in a variety of fields. As an organization begins to develop and implement such models, the data used in the training, validation, and testing of ML models, the model parameters, and the use cases or limitations of the models must be properly stored to ensure models are both fully traceable and used correctly. In the context of predicting material behavior, advances in computationally intense, physics-based modeling of material behavior at various length scales and the emergence of Integrated Computational Materials Engineering (ICME) have driven the need for developing data-driven surrogate models of the physics-based simulation tools using ML techniques. Surrogate model development allows for accurate material behavior prediction at a fraction of the cost of its physics-based counterpart, allowing for multiscale simulations of real-world applications, further enabling the ability to design fit-for-purpose materials for a reasonable computational investment. However, training such models requires extensive data, and thus, effective data management is necessary to reach the full potential that ML can offer to material design and ICME. This paper proposes a generalized, robust schema that allows organizations to store both real (experimental) and virtual (simulation) data used to train ML models and the defining model parameters and architectures within the Granta MI Platform. The developed schema allows for various types of data inputs and outputs, including single point values, time-series data, and images that can be used in the prediction of material behavior, while following outlined best practices for effective data management. An effective schema for ML data and models can help prevent the recreation of virtual/real training data and surrogate models, help reduce the time to create new models similar to existing ones by offering a starting point in the hyperparameter determination stages, minimize resources devoted to verification and validation (V&V) and certification of models, and ensure that data and surrogate models are not misused due to full traceability of both the data and ML model. It also allows organizations access to models that have already been developed, such that they can be used in the design of new materials, enabling the overall goals of ICME.

Brandon L. Hearley↗

Large-Scale Grid Models: Synthetic Data and Co-Simulation

Power grid modernization and wide-spread distributed energy resource (DER) integration are driving an explosion of interest in advanced algorithms and new optimization schemes. However, there has historically been a lack of open-access realistically sized and detailed datasets-particularly for the distribution system-and simulation tools able to model these systems. This talk will present recent advances with very large-scale (>>1M nodes) distribution data sets and the use of co-simulation to tractably model large integrated transmission-distribution grids and their interactions with new controls/optimization.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

The Object Reentry Survival Analysis Tool (ORSAT) code is maintained and used by the NASA Orbital Debris Program Office (ODPO) and has been under continuous development and improvement since the mid-1990s. ORSAT is an object-oriented reentry simulation tool; it models a satellite as a collection of discrete components that follow independent trajectories upon the breakup of the parent object. Version 7.1 of the tool incorporates five years of new thermal and aerodynamic model development, multi-processor parametric study capability, codebase upgrades, and numerous bug-fixes. The thermal demise model was completely rewritten using a forward-time/central-space numerical stencil and incorporating a new pyrolysis model for fiber-reinforced plastic (FRP) materials. New aerodynamic and aeroheating models for hollow cylinders and hollow square prisms were developed using a combination of flow simulations in the direct simulation Monte Carlo (DSMC) Analysis Code (DAC) and Data Parallel Line Relaxation (DPLR) code and free-flight tests in the University of Texas at San Antonio’s Hypersonic Wind Tunnel. The latest version also incorporates a mechanical, strength-based demise model for FRP materials. Minor improvements include an update to the Fortran 2018 codebase; improved integration and speed with the Python-based, multi-core, parametric study tool, AutoORSAT; and fixes for many minor bugs. This new version of ORSAT will enable more accurate reentry risk assessments for modern satellites. This paper presents an overview of these changes and a summary of the verification and validation performed on the final code.

Benton R. Greene↗

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

The Object Reentry Survival Analysis Tool (ORSAT) code is maintained and used by the NASA Orbital Debris Program Office (ODPO) and has been under continuous development and improvement since the mid-1990s. ORSAT is an object-oriented reentry simulation tool; it models a satellite as a collection of discrete components that follow independent trajectories upon the breakup of the parent object. Version 7.1 of the tool incorporates five years of new thermal and aerodynamic model development, multi-processor parametric study capability, codebase upgrades, and numerous bug-fixes. The thermal demise model was completely rewritten using a forward-time/central-space numerical stencil and incorporating a new pyrolysis model for fiber-reinforced plastic (FRP) materials. New aerodynamic and aeroheating models for hollow cylinders and hollow square prisms were developed using a combination of flow simulations in the direct simulation Monte Carlo (DSMC) Analysis Code (DAC) and Data Parallel Line Relaxation (DPLR) code and free-flight tests in the University of Texas at San Antonio’s Hypersonic Wind Tunnel. The latest version also incorporates a mechanical, strength-based demise model for FRP materials. Minor improvements include an update to the Fortran 2018 codebase; improved integration and speed with the Python-based, multi-core, parametric study tool, AutoORSAT; and fixes for many minor bugs. This new version of ORSAT will enable more accurate reentry risk assessments for modern satellites. This paper presents an overview of these changes and a summary of the verification and validation performed on the final code.

Benton R. Greene↗

Ring Model Development and Validation for Prismatic HTGR Core Thermal-hydraulics and Safety Analysis

Because of the complex core geometry, prismatic high temperature gas-cooled reactors (prismatic HTGRs) often exhibit complex thermal fluid behaviors during both normal operating and transient conditions. Most HTGR designs rely on passive safety system for decay heat removal, such as the reactor cavity cooling system (RCCS). During postulated accidents like Pressurized Conduction Cooldown (PCC) event, the decay heat is first radially transferred from the core region to the reactor vessel outer surface, then to the RCCS cooling panels. The peak fuel temperature is controlled by heat transfer mechanisms with two distinctive characteristic length scales, i.e., the core-wise effective heat conduction and local heat conduction in the fuel pellet scale. As both length scales are essential to determine the fuel temperature, from the modeling perspective, computer codes must be able to capture heat transfer in both scales. This is challenging for both computational fluid dynamics (CFD) tools because of extremely large amount of computation resources required, and for system analysis codes because of the challenge to model the complex core geometry. Under the support of DOE-NE’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, efforts have been pursued to support HTGR technology development and its modeling and simulation needs. There is a particular need for advanced modeling and simulation tools to predict thermal-fluid behavior during safety-related transients. In our previous studies, the ring model was adopted in SAM and further developed to simulate the normal operating condition and a PCC event using the MHTGR-350 design of General Atomics as the reference design. This current work represents a continuation of these previous efforts, and the focus is to critically review and examine simplifications and assumptions made to develop the ring model, and to perform code validation using experimental data from an integral-effect test facility, the High Temperature Test Facility (HTTF) at the Oregon State University. In this study, the test PG-27 from the HTTF test suite was selected for code validation purpose. The test PG-27 is a transient test designed to simulate the PCC event of the MHTGR design. Very good agreements between SAM prediction and experimental measurements were found in both coolant and solid structure temperatures during the transient.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Tunable plasmon-enhanced second-order optical nonlinearity in transition-metal dichalcogenide nanotriangles (Final Report for SC0008712)

The control of light-matter interaction at the nanoscale is a grand challenge that cuts across modern photonics, plasmonics, and optoelectronics. The development of simulation tools for predictive modeling of nanostructured light emitters and absorbers is critical to successfully tackling this grand challenge. Existing state-of-the-art tools are not suitable for the following reasons: a) Phenomenological models of materials, commonly employed in the full-wave solutions to Maxwell’s equations, are fit to experimental data for bulk materials and fall short when attempting to analyze nanostructures. b) Nonlinearities in optical response can arise solely from nanostructuring, and require time-dependent quantum electronic transport techniques to capture. c) Emergent materials with exotic and tunable physical properties are increasingly used, but their properties are very sensitive to the substrate, impurities, and edge termination, and require an accurate description of interband and intraband processes, as well as dissipation. d) Microscopic modeling of electronic transport usually employs simplified electrodynamics, and realistic models that couple full electronic transport with full-wave electrodynamics are needed for accurate photonics simulations. The objective of this project was to computational tools that will overcome the limitations faced by current modeling tools and provide an unprecedented level of accuracy for predictive modeling of light-matter interaction at the nanoscale.

36 MATERIALS SCIENCE↗

Assessment of Microreactor Safety Analysis Challenges and Recommendations for Utilization of the Comprehensive Reactor Analysis Bundle

To enable the broad deployment of microreactors in fundamentally new application regimes (i.e., mobile and autonomous operations), their safety must be indisputable in terms of possessing inherent resistance to severe offsite dose consequences. Therefore, mechanistic beyond-design-basis event source term calculations that demonstrate a sufficiently large margin of safety will be required to accommodate these new application regimes, which have no history of commercial regulation. Even for traditional reactor operation configurations, safety analysis expertise and familiarity with accident phenomena and conditions in microreactors—specifically those with heat pipe primary cooling arrangements—are lacking compared with other advanced reactor concepts and small modular reactors. Recently, modeling and simulation tools to account for unique heat pipe design aspects have been developed by Sandia National Laboratories with MELCOR and by the US Department of Energy’s (DOE’s) Office of Nuclear Energy Advanced Modeling and Simulation Program with BlueCRAB. However, further demonstration and assessment of potential knowledge gaps are needed to support these codes’ broad usage by the microreactor community. Through the DOE Microreactor Program, an initial assessment of these two tools and guidance on how an evaluation model could be constructed was performed and is reported herein. Moreover, a proposed approach for demonstrating an evaluation model using these two tools is outlined.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Parameter extraction for a SPICE model of an hTron superconducting thermal switch

Efficiently simulating large circuits is crucial to the development of superconducting nanowire-based electronics. However, current simulation tools for this technology are not adapted to the scaling of circuit size and complexity. We focus on the multilayered heater-nanocryotron (hTron), a promising superconducting nanowire-based switch used in applications such as superconducting nanowire single-photon detector readout. Previously, the hTron was modeled using traditional finite-element methods, which fall short in simulating systems at a larger scale. An empirical-based method would be better adapted to this task, enhancing both simulation speed and agreement with experimental data. In this work, we perform switching current and activation delay measurements on 17 hTron devices. We then develop a method for extracting physical fitting parameters used to characterize the devices. We build a SPICE behavioral model that reproduces the static and transient device behavior using these parameters, and validate it by comparing its performance to a model developed in prior work, showing an improvement in simulation time by several orders of magnitude. Furthermore, our model provides circuit designers with a tool to help understand the hTron’s behavior during all design stages, thus enabling broader use of the hTron across various new areas of application.

Caloritronics↗