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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Networked Microgrid Cybersecurity Architecture Design Guide: A New Jersey TRANSITGRID Use Case

Microgrids require reliable communication systems for equipment control, power delivery optimization, and operational visibility. To maintain secure communications, Microgrid Operational Technology (OT) networks must be defensible and cyber-resilient. The communication network must be carefully architected with appropriate cyber-hardening technologies to provide security defenders the data, analytics, and response capabilities to quickly mitigate malicious and accidental cyberattacks. In this work, we outline several best practices and technologies that can support microgrid operations (e.g., intrusion detection and monitoring systems, response tools, etc.). Then we apply these recommendations to the New Jersey TRANSITGRID use case to demonstrate how they would be deployed in practice.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Evaluating the Thermal Impacts of Inadvertent Export on Service Transformers

As more DER interconnect to the system there are times where the total generation (or load) of a DER cannot be supported by the system. To more quickly allow these DER to interconnect they may need to regulate their output to a different export capacity than their nameplate capacity via a power control system (PCS). In the time it takes PCS to respond, however, an inadvertent export may occur, where the DER operates beyond its export limit. This report evaluates the potential thermal impact such momentary violations may have on service transformers, to determine whether response times should be more tightly controlled or not.

42 ENGINEERING↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2019

Engine-Aftertreatment in Closed-Loop Modeling for Heavy Duty Truck Emissions Control

An engine-aftertreatment computational model was developed to support in-loop performance simulations of tailpipe emissions and fuel consumption associated with a range of heavy-duty (HD) truck drive cycles. For purposes of this study, the engine-out exhaust dynamics were simulated with a combination of steady-state engine maps and dynamic correction factors that accounted for recent engine operating history. The engine correction factors were approximated as dynamic first-order lags associated with the thermal inertia of the major engine components and the rate at which engine-out exhaust temperature and composition vary as combustion heat is absorbed or lost to the surroundings. The aftertreatment model included catalytic monolith components for diesel exhaust oxidation, particulate filtration, and selective catalytic reduction of nitrogen oxides (NOx) with urea. Both the engine and aftertreatment models have been calibrated with dynamometer measurements from a commercial 2010-certificated 15-L Cummins diesel engine. The fuel consumption engine map with the reduced data is attached in the appendix. Simulations with the combined engine and aftertreatment models above appear to reveal important trends among the fuel efficiency, emissions control, power demand for HD trucks under realistic drive cycle conditions. Thus, this type of computational simulation appears to have significant value in choosing among options for HD vehicle design and operation.

Gao, Zhiming↗
NASA NTRS1966

Thermal manikin

Testing of anthropomorphic thermal manikin and temperature logging-power control system

THERMAL SIMULATION↗
NASA NTRS1971

America's Lunar Roving Vehicle

Lunar roving vehicle for Apollo 15 mission, discussing power, control, navigation and deployment systems in relation to lunar exploration requirements

Adams, W. R.↗
NASA NTRS1972

Ground and flight test methods for determining limit cycle and structural resonance characteristics of aircraft stability augmentation systems

Performance criteria and test techniques are applied to stability augmentation systems (SAS) during ground testing to predict objectionable limit cycles and preclude structural resonance during flight. Factors that give rise to these problems, means of suppressing their effects, trade-offs to be considered, and ground test methods that have been developed are discussed. SAS performance predicted on the basis of these tests is compared with flight data obtained from three lifting body vehicles and the X-15 research airplane. Limit cycle and structural resonance test criteria, based upon ground and flight experience and data, were successfully applied to these vehicles. The criteria used were: The limit cycle amplitude (SAS gain multiplied by peak-to-peak angular rate) shall not exceed 0.5 deg for the highest product of control power and SAS gain that will be used in flight; the maximum in-flight SAS gain should never exceed 50 percent of the value at which a structural resonance can be sustained during ground test.

Painter, W. D.↗
NASA NTRS1972

Study of aircraft electrical power systems

The formulation of a philosophy for devising a reliable, efficient, lightweight, and cost effective electrical power system for advanced, large transport aircraft in the 1980 to 1985 time period is discussed. The determination and recommendation for improvements in subsystems and components are also considered. All aspects of the aircraft electrical power system including generation, conversion, distribution, and utilization equipment were considered. Significant research and technology problem areas associated with the development of future power systems are identified. The design categories involved are: (1) safety-reliability, (2) power type, voltage, frequency, quality, and efficiency, (3) power control, and (4) selection of utilization equipment.

Source record↗
NASA NTRS1973

Results of Full-Scale Wind Tunnel Tests on the H.126 Jet Flap Aircraft

The aerodynamic characteristics of the full-scale H.126 jet flap aircraft were studied in a 40- by 80 foot wind tunnel. The H.126 aircraft is designed for research on flight characteristics of an aircraft using the jet flap principle. Static longitudinal, lateral, and directional characteristics were measured at a Reynolds number of 2.5 to 2.7 million. The jet control power as well as the aerodynamic characteristics were measured and are presented herein with limited discussion. The primary configuration variables were flap and aileron deflection.

Aiken, T. N.↗
NASA NTRS1973

C-5A/orbiter wind tunnel testing and analysis: Piggyback ferry

Wind tunnel testing and analytical studies of the feasibility of ferrying the NASA Shuttle Orbiter on the C-5A in a piggyback mode have been accomplished. Testing was conducted in the 8x12 foot low speed wind tunnel using an existing 0.0399 scale C-5A model in conjunction with a NASA 0.0405 scale Orbiter model. Six component force and moment data were measured over a range of pitch and yaw angles to determine lift and drag characteristics, lateral/directional stability characteristics and longitudinal and directional control powers. A description of the wind tunnel test program with a run schedule and the complete plotted data for all the test runs are presented. Initial emphasis was given to determining the effects of the Orbiter above the C-5A and the optimum location for minimum interference on C-5A characteristics. A comprehensive series of cruise configurations were tested including a range of Orbiter longitudinal and vertical locations, incidences, and afterbody fairings. Subsequently, a series of configurations were devised during the test program to determine means of recovering directional stability degradation due to Orbiter interference.

Tomlin, K. H.↗
NASA NTRS1973

Study of dynamics of X-14B VTOL aircraft

Research was initiated to investigate certain facets of modern control theory and their integration with a digital computer to provide a tractable flight control system for a VTOL aircraft. Since the hover mode is the most demanding phase in the operation of a VTOL aircraft, the research efforts were concentrated in this mode of aircraft operation. Research work on three different aspects of the operation of the X-14B VTOL aircraft is discussed. A general theory for optimal, prespecified, closed-loop control is developed. The ultimate goal was optimal decoupling of the modes of the VTOL aircraft to simplify the pilot's task of handling the aircraft. Modern control theory is used to design deterministic state estimators which provide state variables not measured directly, but which are needed for state variable feedback control. The effect of atmospheric turbulence on the X-14B is investigated. A maximum magnitude gust envelope within which the aircraft could operate stably with the available control power is determined.

Loscutoff, W. V.↗
NASA NTRS1973

Orbiting solar observatory /OSO/

Description of the OSO spin-stabilized spacecraft capable of conducting eleven experiments in studying the sun, the earth, and other space objects. The OSO provides controlled electric power, thermal control, a telemetry and command interface, tape-recorded data storage, and precisely timed orbital and orientation information. A chart indicating experiments carried out on nine OSO missions is included.

Oertel, G. K.↗
NASA NTRS1975

Free-flight model investigation of a vertical-attitude VTOL fighter

Tests were made in the Langley full-scale tunnel and included a study of the stability and control characteristics of delta- and swept-wing configurations from hovering through the transition to normal forward flight. Static force tests were also conducted to aid in the analysis of the flight tests. With conventional artificial rate stabilization, very smooth transitions could be made consistently with relatively little difficulty. Because of the lower apparent damping and a tendency to diverge in yaw, however, the swept-wing configuration was considered to be much more difficult to fly than the delta-wing configuration. With rate dampers off, both configurations were very difficult to control and the control power needed for satisfactory flights was substantially higher than with the rate dampers operating.

Newsom, W. A., Jr.↗