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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Deploying Taller Turbines in Complex Terrain: A Hill Flow Study (HilFlowS) Perspective

Terrain-induced flow acceleration is presented for the summertime, peak power season at Lawrence Livermore National Laboratory’s Site 300 for the Hill Flow Study (HilFlowS). HilFlowS, designed as an adjunct field campaign to the Department of Energy’s Second Wind Forecasting Improvement Project (WFIP2), provides wind profile observations at a second location in complex terrain for validating numerical atmospheric model simulations and for better understanding flow behavior over hills for wind power generation. One unique feature of HilFlowS was the inclusion of an undergraduate university student who helped plan and execute the experiment as well as analyze wind data from two remote sensing laser detection and ranging (lidar) instruments deployed along parallel ridgelines. HilFlowS examines the trend of building higher into the atmosphere for the purpose of increasing wind turbine power production and evaluates the wind resource in the Altamont Pass Region of Northern California for a set of wind turbines of differing hub-heights and rotor-disk diameters found in the area. The wind profiles show strongly channeled onshore flow above both hills, enhanced by strong subsidence aloft, which produces a wind maximum (Umax) around z = 10 m and strong negative shear throughout all of the evaluated rotor-disks for much of the summer wind season. Under these conditions, shear becomes more negative with increasing hub-height and increasing rotor-disk size. Rotor-disk equivalent wind speed (Uequiv), a measure of the average wind speed across the entire rotor-disk, is compared to hub-height, rotor length, and rated capacity factor for the set of turbines. Uequiv is most closely related to turbine hub-height and is negatively correlated given the low altitude of Umax. Based on these results, building the largest capacity, large rotor-disk wind turbine at the lowest possible hub-height appears to provide turbines in the Altamont with a fast, near-surface, onshore wind resource during the peak power season.

17 WIND ENERGY↗
DOE OSTI2023

Data-Driven Approaches for Bead Geometry Prediction Via Melt Pool Monitoring

In the realm of additive manufacturing, the selection of process parameters to avoid over and under deposition entails a time-consuming and resource-intensive trial-and-error approach. Given the distinct characteristics of each part geometry, there is a pressing need for advancing real-time process monitoring and control to ensure consistent and reliable part dimensional accuracy. Here, this research shows that support vector regression (SVR) and convolutional neural network (CNN) models offer a promising solution for real-time process control due to the models’ abilities to recognize complex, non-linear patterns with high accuracy. A novel experiment was designed to compare the performance of SVR and CNN models to indirectly detect bead height from a coaxial image of a melt pool from a single-layer, single bead build. The study showed that both SVR and CNN models trained on melt pool data collected from a coaxial optical camera can accurately predict the bead height with a mean absolute percentage error of 3.67% and 3.68%, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Improving Building Footprint Extraction Using NAIP and 3DEP Lidar Derived Features with Deep Learning

Accurate building footprint extraction is critical for applications ranging from population estimation to disaster management. Although optical imagery provides detailed spectral information, it often struggles with shadows, occlusions, and background clutter in dense urban environments. Lidar data, by contrast, offer precise elevation and structural attributes but face challenges such as variable point density and noise. This study integrates multispectral imagery from the U.S. Department of Agriculture (USDA) National Agriculture Imagery Program (NAIP) with lidar-derived feature height and intensity from the U.S. Geological Survey (USGS) 3D Elevation Program (3DEP) to improve footprint extraction using a U-Net–based deep learning model. A six-band input stack (RGB, near-infrared, height, intensity) was developed, normalized, and tiled for training and evaluation against Microsoft Global Building Footprints (GBF). Results from the Houston, TX test site show that the six-band model achieved a precision of 0.86, recall of 0.88, F1 score of 0.87, and Intersection-over-Union (IoU) of 0.76, consistently outperforming four-band baselines by reducing false positives while maintaining sensitivity. Predictions on withheld Houston tiles confirmed strong within-region generalization, yielded a precision of 0.78, recall of 0.81, F1 score of 0.79, and IoU of 0.66. Qualitative analysis further revealed limitations stemming from both training label quality and vegetation–building confusion. These findings demonstrate the complementary value of integrating spectral and structural information for robust building footprint extraction and how domain adaptation strategies can be used to enhance cross-regional transferability.

Liu, Jung Kuan [United States Geological Survey (U↗
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Scaling trends for balance-of-system costs at land-based wind power plants: Opportunities for innovations in foundation and erection

Wind power plant sizes, hub heights, and turbine ratings have increased since 2008 to optimize the cost and performance of wind power; however, the limits of these economies of scale remain unclear. Here, we explore how the costs incurred to install turbines at a wind power plant—the balance-of-system (BOS) costs—scale with turbine rating, hub height, and plant size. We also investigate how these changes in BOS costs influence the levelized cost of energy (LCOE). We show that increasing the plant size from 150 to 400 MW could reduce the BOS costs by 21%. We also show that if the foundation costs decreased by 50%, building a wind power plant with 5-MW turbines (having rotor diameters of 166 m and hub heights of 120 m) could decrease the LCOE by 5%. These results could help inform future BOS cost-reduction opportunities and thereby reduce future capital costs for land-based wind power.

17 WIND ENERGY↗
DOE OSTI2024

Resource Assessment for Distributed Wind Energy: An Evaluation of Best-Practice Methods in the Continental US

Current wind resources within the United States (US) indicate a potential to profitably install nearly 1,400 gigawatts of distributed wind (DW) capacity. This amount is equivalent to over half of the United States’ current energy demand from electricity, making it enough to power millions of homes and businesses and replace countless fossil fuel-based generating plants. Despite the potential growth of DW in the US, deployments are presently hindered by a lack of confidence in resource estimation methods. One potential challenge is that smaller-scale turbines, with hub heights of 40 meters or less, are disproportionately impacted by obstacles such as buildings and vegetation. These obstacles may produce complex wake effects, best modeled with high-fidelity complex fluid dynamics (CFD) models that are too computationally expensive to use for routine siting and resource assessment. Thus, installers today make use of heuristics and simple equations to approximate the impact of obstacles while also leveraging long-term resource data from commercial or publicly available atmospheric models. This study evaluates these historical and commonly used methods alongside new lower-order obstacle models produced from CFD simulations and measurement-based bias correction. The preliminary results from this study show the importance of taking care in the choice and application of mesoscale atmospheric models and the significant value of bias correction using measurements from nearby meteorological towers. Detailed obstacle modeling provides only modest additional gains in performance and, in some cases, can add error, especially at sites where turbines have already been located to avoid obvious impact from upwind obstacles. These findings reinforce the importance of collecting in situ measurements and suggest that obstacle models may be better applied in practice to automated or computer-aided siting, rather than in economic wind resource assessments.

17 WIND ENERGY↗
DOE OSTI2024

Spatiotemporally Registered In-Situ and Ex-Situ Datasets for Laser-based Blown Powder Directed Energy Deposition

This dataset is comprised of in situ sensing data collected during laser-based, blown powder directed energy deposition (DED) of Inconel 718 representing eight different printing conditions: (1) nominal, (2) +15% scan speed, (3) +12% laser power, (4) +42% powder feed rate, (5) +100% jerk limit, (6) +10% layer height, (7) +20% hatch spacing, (8) +20% carrier gas flow. All eight DED builds constructed an identical test coupon geometry consisting of geometric features representative of industrial print requirements (e.g., bulk deposition, thin walls, overhangs). In situ data consists of xyz-coordinates (100 Hz) and on-axis melt pool camera video (60 Hz), both of which have been temporally synchronized to spatially map the melt pool camera data. In addition, post-build X-ray computed tomography (XCT) data for each of the eight test geometries have been spatially registered to the recorded xyz-coordinates, allowing for comparisons between melt pool camera data and flaws identified in the XCT data.

additive manufacturing↗
DOE OSTI2022

Reducing the Overnight Capital Cost of Advanced Reactors Using Equipment-Level Seismic Protective Systems

Consideration of the effects of earthquake shaking on the design and construction of nuclear power plants adds substantially to the overnight capital cost, with anecdotal estimates as high as 35+%, attributed to additional construction materials, need for one-off and sub-optimal designs of equipment due to conflicting design choices, the high cost of seismic qualification of equipment, and regulatory review. Safety-critical equipment in large light water reactors is designed and qualified for seismic demands imposed by the supporting reactor building, optimal mechanical designs are not possible, and designs of a given piece of equipment may vary with height above grade. Similar negative impacts are expected for advanced reactors unless the seismic design paradigm is changed. The overarching goal of this transformational MEITNER project, which involved a multidisciplinary engineering team and designers of three fundamentally different advanced reactors, was to adapt proven seismic isolation and damping technologies to operationalize modular protective systems for safety-class equipment inside advanced reactor buildings. Such seismic protective systems would be tightly integrated into design development for reactor support systems and balance-of-plant construction. The adoption of the technology, which is widely used in non-nuclear sectors, would simplify plant design, enable the use of standardized equipment and buildings, optimized for operational performance, and reduce plant size and weight. The need for site-specific equipment would be eliminated, enabling identical equipment to be used across multiple plants sited across the US and economies of scale, and catalyzing new interest and investment. The equipment-based protective systems would allow siting of advanced reactors in regions of high seismic hazard.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Urban-scale Energy Modeling: Scaling Beyond Tax Assessor Data

In an attempt to attain building-specific characteristics for urban-scale building energy models, county-specific tax assessors’ data is often an initial data source. This data source can contain valuable information such as year built, area, height, HVAC type, and roof/wall descriptions.We will show examples of 2,000 fields from Hamilton County in Tennessee with examples of many fields which are not relevant to urban-scale building energy modeling, are incorrect compared to other data sources, and highlight some lessons learned working with such a data source.There are currently 3,142 counties in the United States, each with their own data format, field definitions, and data access policy. As urban-scale involves city-scale analysis potentially covering multiple counties and matures toward state- or nation-scale analysis, county-by-county approaches are not scalable. While there are efforts to unify these datasets, there is an increasing proliferation of data and algorithms that can cover wider areas and provide more accurate inputs for urban-scale models. This paper summarizes computer vision of imagery, cartographic layers, building type assessment, and model generation used to achieve scalable detection and analysis of buildings.

New, Joshua↗
DOE OSTI2022

High-throughput, in situ imaging of multi-layer powder-blown directed energy deposition with angled nozzle

Laser metal additive manufacturing (AM) has become an increasingly popular technology due to its flexibility in geometry and materials. As one of the commercialized additive processes, powder-blown directed energy deposition (DED) has been used in multiple industries such as aerospace, automotive, medical device, etc. However, a lack of fundamental understanding remains for this process, and many opportunities for alloy development and implementation can be identified. A high-throughput, in situ DED system capable of multi-layer builds that can address these issues is presented here. In this work, implications of layer heights and energy density are investigated through an extensive process parameter sweep, showcasing the power of a high-throughput setup while also discussing multi-layer interactions.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

A dynamic model of wind turbine yaw for active farm control

This paper presents a graph-based dynamic yaw model to predict the dynamic response of the hub-height velocities and the power of a wind farm to a change in yaw. The model builds on previous work where the turbines define the nodes of the graph and the edges represent the interactions between turbines. Advances associated with the dynamic yaw model include a novel analytical description of the deformation of wind turbine wakes under yaw to represent the velocity deficits and a more accurate representation of the interturbine travel time of wakes. The accuracy of the model is improved by coupling it with time- and space-dependent estimates of the wind farm inflow based on real-time data from the wind farm. The model is validated both statically and dynamically using large-eddy simulations. An application of the model is presented that incorporates the model into an optimal control loop to control the farm power output.

17 WIND ENERGY↗
DOE OSTI2025

Collaborative Proposal: Improving understanding of the internal structure and dynamics of deep convection using ARM observations and large eddy simulations

Recent observational and large eddy simulation (LES) modeling studies have nearly unanimously supported the view of deep cumulus convection being composed of a series of quasi-spherical bubbles of buoyant air, known as moist thermals. Despite the prevalence of moist thermals in deep convection, a comprehensive theory for the dynamics of these structures is lacking. Most current conceptual models for cumulus convection are based on canonical scaling theories for dry thermals or plumes; however, there is considerable evidence that the behavior of moist thermals differs markedly from these theories. Furthermore, the theoretical basis for most cumulus parameterizations originates from the plume conceptual model, and therefore these parameterizations are inconsistent with the real structure of moist convection. Motivated by the aforementioned knowledge gaps, this “end-to-end” research effort use theory, observations, numerical simulations, and direct improvements to the Zhang-McFarlane (ZM) convection scheme in the global climate Community Atmosphere Model (CAM) to address the following research questions: What key environmental parameters determine whether or not shallow convection will transition into deep convection, in the context of thermal-like updrafts? What factors regulate the size of thermals within cumulus updrafts? How does vertical wind shear influence thermal behavior, and as a consequence, vertical velocity and mass flux profiles and the shallow-to-deep convective transition? What are the critical processes that determine updraft vertical velocities and their connection to the vertical mass flux profile for thermal-like updrafts? Idealized LES modeling will be used in conjunction with theoretical models for the core properties of thermal-like updrafts to better understand key processes that regulate thermal ascent rates and entrainment properties. Thermal-tracking procedures will be used to characterize the behavior of thermals within the LES, and recently developed direct measures of entrainment and detrainment will be used to quantify entrainment/detrainment rates. Building from these results, we will analyze the structure of moist thermals from hemispheric range-height indicator scans taken during the Atmospheric Radiation Measurement Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign, and from “real case” LES of CACTI events. This combined modeling and observational analysis will provide essential validation for the existing body of research on moist thermal dynamics, which is based primarily on modeling studies. With the insight gained from the aforementioned activities, we will modify the Zhang-McFarlane convection scheme to improve its representation of updraft vertical velocity and entrainment rate profiles. These process-level changes will be tested in the Community Atmosphere Model to assess the impact on global climate simulations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Restructuring and Optimizing Reactor Building Lifting Processes & Designing a Solution for an Overhead Door Handling Forklift Attachment

This poster presents two innovative projects aimed at enhancing operational efficiency and safety at the Advanced Test Reactor (ATR) Complex. The first project focuses on restructuring the existing lift book used for hoisting operations within the ATR Reactor Building. The current lift book, a cumbersome 150+ page document, is being transformed into a more efficient format using charts that allow for quick identification of maximum lift heights based on object footprint and weight. This new method also considers various parameters such as floor integrity and reactor status, dividing entries into four distinct charts to improve usability and safety during lifts. The second project involves designing a specialized forklift attachment for handling an overhead door at the ATR Reactor Building. The attachment is engineered to securely lift and lower a 1200lb, 14ft long door, ensuring safe replacement operations. The design process included research on forklift attachment codes, modeling in Autodesk Inventor, and testing through Finite Element Analysis (FEA) and hand calculations to confirm the attachment's structural integrity. Future work includes completing detailed drawings and an Engineering Calculations Analysis and Review (ECAR) document to proceed with manufacturing and assembly. Together, these projects demonstrate a commitment to optimizing reactor building operations through innovative engineering solutions and safety considerations.

42 - ENGINEERING↗
DOE OSTI2021

The research into the propagation law of the shock wave of a gas explosion inside a building

Based on the dissipation rate conservation equations of turbulent kinetic energy in the k‐ ε turbulence model, a complicated three‐dimensional finite element model of a kitchen filled with gas mixture is developed by using the open source field operation and manipulation (OpenFOAM). Two representative kitchens were used to investigate the propagation law of the shock wave of a gas explosion inside a building by considering the key characteristics of the blast shock wave. The influence of some crucial parameters, such as initial conditions and kitchen parameters, on the properties of the blast shock wave is investigated. The basic steps to predict the peak pressure of the blast shock wave are given in consideration of the initial condition and the kitchen whilst the injury effect of the blast shock wave on the humans and animals is evaluated. The research results indicate that the pressure time history and the peak pressure space distribution are greatly influenced by the kitchen design layout. The coupled interaction between the initial temperature and gas volume concentration, especially at the upper and lower explosion limits of the gas, significantly affects the peak pressure. The peak pressure varies significantly with the opening and the buffer; however, it has little relation with the width, length, and height of the kitchen. The proposed method can accurately and effectively predict the peak pressure of the blast shock wave inside buildings. In terms of the peak pressure space distribution of the explosion shock wave, the peak pressure is much higher than the threshold of the killing pressure, which is unsafe for the humans and animals in the building.

Lin, Shu-Chao↗
DOE OSTI2022

Suppression of Superconductivity and Nematic Order in Fe 1–y Se 1–x S x (0 ≤ x ≤ 1; y ≤ 0.1) Crystals by Anion Height Disorder

Connections between crystal chemistry and critical temperature T c have been in the focus of superconductivity, one of the most widely studied phenomena in physics, chemistry and materials science alike. In most Fe-based superconductors materials chemistry and physics conspire so that T c correlates with the average anion height above the Fe plane, i.e. with the geometry of the FeAs 4 or FeCh 4 (Ch = Te, Se, S) tetrahedron. Here, by synthesizing Fe 1-y Se 1-x S x (0 ≤ x ≤ 1, y ≤ 0.1) we find that in alloyed crystals T c is not correlated with the anion height as most other Fe superconductors. Instead, changes in T c (x) and tetragonal-to-orthorombic (nematic) transition T s (x) on cooling are correlated with disorder in Fe vibrations in direction orthogonal to Fe planes, along the crystallographic c-axis. The disorder stems from the random nature of S substitution, causing deformed Fe(Se,S) 4 tetrahedra with different Fe-Se and Fe-S bond distances. Our results provide evidence of T c and T s suppression by disorder in anion height. The connection to local crystal chemistry may be exploited in computational prediction of new superconducting materials with FeSe/S building blocks.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Grain structure and texture selection regimes in metal powder bed fusion

Additive manufacturing (AM) offers opportunities to produce complex part geometries not possible with conventional processing and in some cases even improve part performance. However, adoption has been slowed by difficulties assessing microstructure variability and there is no straightforward approach to relate processing to grain structure characteristics. In this study, datasets from AdditiveFOAM heat transport simulations of laser powder bed fusion (LPBF) are used to drive ExaCA simulations of grain structure. The GPU utilization of ExaCA and an algorithmic update for modeling melt pool overlap region solidification enabled rapid and parallel simulation across a wider range of process conditions than previously explored with cellular automata-based solidification models. A texture selection angle $θ_s$ is defined based on melt pool overlap geometry, and the range of $θ_s$ over which a commonly observed texture transition occurs in characterized AM builds was well-reproduced by ExaCA simulations over a wide range of melt pool shape, hatch spacing, and layer height. ExaCA simulations with 90 degree rotation of the scan direction on every other layer reproduced a number of trends from the AM literature including grain refinement, the dominance of layers with larger melt pools on the final grain structure, and the weakening or strengthening of texture depending on odd and even layer melt pool overlap geometry. EBSD data from a benchmark AM part is used to validate the simulated mechanism of a layer rotation-induced texture strengthening effect. Importantly, these results expand the understanding of the mechanisms for texture selection in alloys with cubic crystal symmetry and offer an approach to easily evaluate processing conditions. With this new understanding, these modeling tools will enable anticipation of previously unexpected variations in grain structure and target specific microstructures and properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Lab Evaluation of Downward Capacity of Radiant Ceiling Panel Systems

This project investigated the cooling delivery effectiveness of radiant ceiling panels as a function of attic insulation level using multiple laboratory testing and analytical methodologies. Delivery effectiveness is the heating or cooling energy delivered to a conditioned space divided by the total heating or cooling energy added or removed by the space conditioning system. The lower the losses of the heating or cooling delivery method, the higher the delivery effectiveness. For ducted systems, delivery effectiveness is reduced by both air leakage and thermal losses (especially if the ducts are installed in attics), while the delivery effectiveness of a radiant system supplied by hot and cold water is only reduced by thermal losses, which can be mitigated by sufficient insulation above, or at the "back" of the panel. Being installed at or below the ceiling plane, sufficient back insulation should be provided by default in the form of the attic insulation above the radiant ceiling panels. Site-built radiant ceiling panels were evaluated at Frontier Energy’s Building Science Research Laboratory (BSRL) in a uniquely designed environmental test chamber with independently controllable indoor and attic spaces and a height-adjustable ceiling.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

BoxScore - A real-time beam-diagnosis program for the CAEN digitizer x730 series

BoxScore is a real-time beam diagnosis and monitoring program for the CAEN x730 series digitizer, developed for the ATLAS in-flight system at Argonne National Laboratory. The CAEN x730 series digitizer, with built-in Digital Pulse Processing for the Pulse-Height-Analysis, digitizes the input signal in real-time and processes it using a trapezoidal filter. BoxScore reads the digitizer’s buffer directly, builds and saves events to local files, plots histograms for particle identification, and outputs the rates of selected isotopes every second. Implementation of BoxScore has shortened the time needed for in-flight beam-tuning and has potential applications for other nuclear physics experiments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗