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NASA NTRS2023

Quiet Spacecraft Cabin Ventilation Fan: Vibration Measurements Results

Quiet, efficient fans with minimal vibrations are needed to maximize the mechanical life of atmospheric revitalization system fans used for human life support systems for long duration space exploration missions. Several metal spacecraft cabin ventilation fan prototypes have been designed, built, and tested at the NASA Glenn Research Center Acoustical Testing Laboratory. Tests performed in 2021 of the first prototype of the metal fan measured vibrations greater than desired at design point speed and backpressure conditions. To try to reduce those vibrations, a second prototype of the fan design was developed which included a new lighter rotor with a tighter balance tolerance, a new collet to attach the rotor to the motor shaft more securely and repeatably, and a new bracket to center and hold the motor in the fan centerbody more precisely. The second prototype of the fan was tested in 2023 and the vibrations were measured with the fan operating at design point speeds in isolation but not throttled to design point back pressure conditions since it was not installed with inlet and exhaust ducting. Peak vibration was reduced from 4 mm/s to 1 mm/s. This paper is part of a series of reports documenting the performance of the prototype fan.

Fan↗

DOE OSTI2016

A Deep Generative Deconvolutional Image Model

A deep generative model is developed for representation and analysis of images, based on a hierarchical convolutional dictionary-learning framework. Stochastic unpooling is employed to link consecutive layers in the model, yielding top-down image generation. A Bayesian support vector machine is linked to the top-layer features, yielding max-margin discrimination. Deep deconvolutional inference is employed when testing, to infer the latent features, and the top-layer features are connected with the max-margin classifier for discrimination tasks. The model is efficiently trained using a Monte Carlo expectation-maximization (MCEM) algorithm; the algorithm is implemented on graphical processor units (GPU) to enable large-scale learning, and fast testing. Excellent results are obtained on several benchmark datasets, including ImageNet, demonstrating that the proposed model achieves results that are highly competitive with similarly sized convolutional neural networks.

convolutional neural network↗

DOE OSTI2018

Methods for operating solar-thermochemical processes

Methods for controlling or operating solar thermochemical reactions process that maximize the two-step thermochemical energy cycle efficiency by a combination of pressure and temperature swing are disclosed.

Ermanoski, Ivan↗

DOE OSTI2020

Methods for operating solar-thermochemical processes

14 SOLAR ENERGY↗

DOE OSTI2021

Performance of a Hybrid HVAC-Integrated Thermal Storage Device

Thermal equipment in buildings is a primary contributor to peak loads on the electrical grid. Thermal energy storage is a cost-effective strategy to decouple electric use from thermal loads, thus reducing grid peak costs for building owners. One method for storing thermal energy in a building is to integrate a phase change material (PCM) directly into the heating, ventilation, and air conditioning system. These systems often require additional glycol loops, pumps, valves, and heat exchangers to couple the storage to the cooling system and building space, which increases the complexity and cost. This work will discuss an alternate approach where the storage is added directly into the heat pump evaporator. A detailed two-dimensional finite difference heat transfer model of a PCM-refrigerant-glycol heat exchanger was developed to simulate the performance of this component. The fluid stream was discretized along the flow direction to capture changes in the fluid properties and local heat transfer rates, and the phase change material was discretized in both the x and y directions to capture the movement of the melt front. The model was used to understand the impact of different material and geometric properties on the charge and discharge characteristics of the device. Finally, a Ragone framework analogous to that used for electrochemical batteries was used to maximize the energy density and round-trip efficiency of the device while supplying loads appropriate for space cooling in buildings.

buildings↗

DOE OSTI2023

Assessment of UTP A 2133 Mn as a Matching Filler Metal for Alloy 800H in Section III, Division 5 Applications

Six alloys are qualified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) for elevated-temperature nuclear components. Due to reactor design alloy restrictions and motivation to improve operational efficiency and plant lifetimes, it is necessary to maximize the usefulness of qualified alloys. One of these alloys is Alloy 800H, which is qualified for a maximum temperature of 760°C and a maximum 300,000-hour service life. However, the welding filler metals qualified to join Alloy 800H have stress rupture factors that reduce the allowable weldment strength by factors as low as 0.59 times the Alloy 800H base metal. In an effort to improve the weldment creep-rupture performance, or to increase the stress reduction factor, non-code qualified filler metals are under investigation by the Department of Energy?s Advanced Reactor Technologies program. For this investigation, UTP A 2133 Mn filler metal (Fe-Cr-Ni-Mn-Nb) was used to join 0.5 in. thick Alloy 800H plate to demonstrate passing an ASME BPVC Section IX weld qualification. The multi-pass, pulsed GTAW process showed successful weld qualification results, and additional property measurements were conducted to compare previous analyses of Alloy 82 and Alloy 617 filler metals. Future work will evaluate the cross-weld creep-rupture performance of the UTP A 2133 Mn in comparison to Alloy 82 and Alloy 617 filler metals.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

The Role of Competitions in Speeding Energy-Efficient Technology Development and Adoption

This conference paper, which will be submitted for publication in the 2020 ACEEE Summer Study on Energy Efficiency in Buildings, describes competition approaches used by the U.S. Department of Energy (DOE) Building Technologies Office (BTO) and other government agencies to encourage the development and adoption of innovative new energy-efficient, high-performing products while spurring external competition to maximize limited resources. The competition model helps to disrupt traditional thinking and introduce, expand, and evolve what’s possible within limited resource conditions. DOE BTO has sponsored technology competitions, including campaigns, challenges, prizes, and technology procurements to speed the uptake of more efficient refrigerators, clothes washers, air conditioners, and many types of highly efficient lighting technologies, including compact fluorescent lamps (CFLs) and light-emitting diode LED-based home and office luminaires, replacement lamps, and street lighting. In this paper, we will draw upon the technology competition frameworks employed by DOE BTO to support ongoing research and development efforts to illustrate the differences between the approaches and to identify which type is likely to be the most effective in a given technology status and market context. We’ll also share examples of the various technology competition types and results. A question-and-answer table helps readers compare and contrast the four competition types. The paper concludes with a summary of lessons learned from past DOE BTO competitions. The paper will be available in the ACEEE 2020 Summer Study proceedings and a related presentation will be given at the conference.

U.S. Department of Energy Building Technologies Of↗

NASA NTRS2010

Fuel Efficient Strategies for Reducing Contrail Formations in United States Air Space

This paper describes a class of strategies for reducing persistent contrail formation in the United States airspace. The primary objective is to minimize potential contrail formation regions by altering the aircraft's cruising altitude in a fuel-efficient way. The results show that the contrail formations can be reduced significantly without extra fuel consumption and without adversely affecting congestion in the airspace. The contrail formations can be further reduced by using extra fuel. For the day tested, the maximal reduction strategy has a 53% contrail reduction rate. The most fuel-efficient strategy has an 8% reduction rate with 2.86% less fuel-burnt compared to the maximal reduction strategy. Using a cost function which penalizes extra fuel consumed while maximizing the amount of contrail reduction provides a flexible way to trade off between contrail reduction and fuel consumption. It can achieve a 35% contrail reduction rate with only 0.23% extra fuel consumption. The proposed fuel-efficient contrail reduction strategy provides a solution to reduce aviation-induced environmental impact on a daily basis.

Sridhar, Banavar↗

DOE OSTI2022

MoS 2 nanosheet integrated electrodes with engineered 1T-2H phases and defects for efficient hydrogen production in practical PEM electrolysis

Low electrical conductivity and poor accessibility of MoS 2 reaction sites raise great challenges in maximizing the triple-phase-boundary (TPB) sites of MoS 2 -based electrodes and minimizing ohmic losses for efficient hydrogen evolution reaction (HER) in practical proton exchange membrane (PEM) water electrolysis. Herein, we report a scalable hydrothermal approach to fabricate ionomer-free integrated electrodes with engineered 1 T-2 H heterophase and defect-rich MoS 2 nanosheets (MoS 2 NSs) in-situ grown onto the carbon fiber paper (CFP). With an ultralow loading of 0.14 mg/cm 2 , a small voltage of 2.25 V was obtained at 2000 mA/cm 2 in a practical cell with Nafion115 membrane, which outperforms all previously reported high-loading non-precious catalyst-based electrodes. Impressively, it shows 44 times higher mass activity than a high-loading and ionomer-mixed MoS 2 assemblies electrode. Furthermore, this work builds a bridge from catalyst optimization to electrode fabrication and provides a promising direction for improving intrinsic catalytic activity, electrode conductivity and stability for practical PEM water electrolysis.

1T-2H heterophase↗

DOE OSTI2021

A Power Take-Off (PTO) for Wave Energy Converters Based on the Hybrid Hydraulic-Electric Architecture (HHEA)

Wave energy is a promising renewable energy resource for coastal regions around the world, but is not yet an economically competitive source of electricity. More effective power take-off (PTO) designs would help to make wave power a feasible and clean source of energy. To do this, PTOs need to: i) enable controlled actuation, ii) convert absorbed energy into electricity efficiently, and iii) have minimal manufacturing costs. We propose a new PTO architecture that can exert arbitrary control loads on the WEC to maximize energy capture, enabling the downsizing of expensive electrical components while maintaining high efficiency. Our PTO design is based upon a hybrid hydraulic-electric architecture (HHEA). This paper compares the performance of the HHEA PTO against two other PTO designs: 1) a baseline PTO consisting of a system of rectifying check valves and accumulators, and 2) a PTO consisting of an electro-hydraulic actuator (EHA). The HHEA PTO is shown to produce much more power than the check valve PTO and the EHA PTO. Also, the required electric generator sizes for the HHEA are smaller than that of the EHA PTO. The reduced size of these components allows for a WEC which is less expensive to manufacture.

16 TIDAL AND WAVE POWER↗

DOE OSTI2019

Constructive molecular configurations for surface-defect passivation of perovskite photovoltaics

Surface trap-mediated nonradiative charge recombination is a major limit to achieving high-efficiency metal-halide perovskite photovoltaics. The ionic character of perovskite lattice has enabled molecular defect passivation approaches through interaction between functional groups and defects. However, a lack of in-depth understanding of how the molecular configuration influences the passivation effectiveness is a challenge to rational molecule design. In this work, the chemical environment of a functional group that is activated for defect passivation was systematically investigated with theophylline, caffeine, and theobromine. When N-H and C=O were in an optimal configuration in the molecule, hydrogen-bond formation between N-H and I (iodine) assisted the primary C=O binding with the antisite Pb (lead) defect to maximize surface-defect binding. A stabilized power conversion efficiency of 22.6% of photovoltaic device was demonstrated with theophylline treatment.

14 SOLAR ENERGY↗

DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

High-efficiency, anode-free lithium–metal batteries with a close-packed homogeneous lithium morphology

Anode-free lithium–metal batteries (LMBs) are ideal candidates for high-capacity energy storage as they eliminate the need for a conventional graphite electrode or excess lithium–metal anode. Current anode-free LMBs suffer from low Coulombic efficiency (CE) due to poor lithium stripping efficiency. Advanced electrolyte development is a promising route to maximize lithium plating and stripping CE and minimize capacity fade. However, a poor understanding of the mechanisms by which advanced electrolytes improve performance hampers progress in the practical development of anode-free LMBs. Here, we use synchrotron techniques and other tools to analyze the influence of three commercially available electrolytes on the composition, heterogeneity, kinetics, morphology, and electrochemistry of anode-free LMBs. Advanced electrolytes improve the electrochemical performance of anode-free LMBs by forming much denser and better-packed Li morphologies on a Cu current collector than on the conventional electrolyte. Li plates uniformly over the electrode area with the advanced electrolytes rather than in a few active sites. Inactive crystalline Li with heterogeneous distribution dominates the capacity degradation of anode-free cells, especially with the conventional electrolyte, indicating that reducing the amount of “dead” crystalline Li will significantly improve the cycling stability of anode-free cells. Finally, the understanding of the Li plating and stripping process obtained from this work will accelerate the development of anode-free LMBs with high efficiency.

25 ENERGY STORAGE↗

DOE OSTI2025

Thermomechanical Separation of Biogenic and Non-biogenic Carbon from Non-Recyclable MSW

The effective separation of biogenic and non-biogenic carbon from non-recyclable municipal solid waste (n-MSW) presents a significant challenge in the United States. Currently, there are no efficient methods available to address this issue, hindering the potential for maximizing waste utilization and reducing landfilling rates. This project aims to develop and implement a combine thermomechanical separation techniques to separate biogenic and non-biogenic carbon within n-MSW, ultimately facilitating greater resource recovery and enhancing the efficiency and environmental impact of waste management practices.

09 - BIOMASS FUELS↗

DOE OSTI2017

Bioenergy sorghum crop model predicts VPD-limited transpiration traits enhance biomass yield in water-limited environments

Bioenergy sorghum is targeted for production in water-limited annual cropland therefore traits that improve plant water capture, water use efficiency, and resilience to water deficit are necessary to maximize productivity. A crop modeling framework, APSIM, was adapted to predict the growth and biomass yield of energy sorghum and to identify potentially useful traits for crop improvement. APSIM simulations of energy sorghum development and biomass accumulation replicated results from field experiments across multiple years, patterns of rainfall, and irrigation schemes. Modeling showed that energy sorghum’s long duration of vegetative growth increased water capture and biomass yield by ~30% compared to short season crops in a water-limited production region. Additionally, APSIM was extended to enable modeling of VPD-limited transpiration traits that reduce crop water use under high vapor pressure deficits (VPDs). The response of transpiration rate to increasing VPD was modeled as a linear response until a VPD threshold was reached, at which the slope of the response decreases, representing a range of responses to VPD observed in sorghum germplasm. Simulation results indicated that the VPD-limited transpiration trait is most beneficial in hot and dry regions of production where crops are exposed to extended periods without rainfall during the season or to a terminal drought. In these environments, slower but more efficient transpiration increases biomass yield and prevents or delays the exhaustion of soil water and onset of leaf senescence. The VPD-limited transpiration responses observed in sorghum germplasm increased biomass accumulation by 20% in years with lower summer rainfall, and the ability to drastically reduce transpiration under high VPD conditions could increase biomass by 6% on average across all years. This work indicates that the productivity and resilience of bioenergy sorghum grown in water-limited environments could be further enhanced by development of genotypes with optimized VPD-limited transpiration traits and deployment of these crops in water limited growing environments. As a result, the energy sorghum model and VPD-limited transpiration trait implementation aremade available to simulate performance in other target environments.

09 BIOMASS FUELS↗

DOE OSTI2024

Ultra-compact and efficient heat exchanger for solar desalination with unprecedented scaling resistance

The objective is to design, prototype, and test a heat exchanger technology with an efficiency improvement of more than 150% compared to state-of-the-art heat exchanger technology (UA/volume), with significantly improved fouling/scaling resistance at elevated temperatures (>120°C) when compared to existing technology where scaling is a major performance-limiting issue, as well as at lower operating-temperatures (~63-110°C). We now report our overall progress on the project. An ultra-compact, efficient heat exchanger geometry has been developed that can maximize surface-area-to-volume ratio so that proposed target (UA/volume). Advanced manufacturing techniques, such additive manufacturing, have made it possible to create complex structures cost effectively. In addition to traditional manufacturing methods, additive manufacturing has been successfully used for the development of high-performance geometries. These methods allow the ability to create custom surface textures, which are deployed to dramatically control wettability and create energy-gradient surfaces. These techniques allow fouling/scaling nucleation to be spatially controlled, such that as the fouling layer grows it will be broken and removed by flow forces.

42 ENGINEERING↗

NASA NTRSDate not supplied

Robust and Mass Efficient Thermal Protection Systems for Future Venus Missions

Several international Venus missions, both orbiter, and in-situ probe are in the works after a prolonged absence. Future missions are expected to be long-duration lander missions and balloon missions to investigate the cloud layer. The entry mass for these in-situ missions will be significantly higher, and the aeroshell will be larger, than previous missions. Two cardinal requirements govern the selection and use of thermal protection systems (TPS), namely, robustness to assure mission safety during entry and mass efficiency so that the useful mass for science is maximized. One cannot trade mission safety for mass when it comes to TPS. The robustness of the TPS is a paramount requirement as it is a single point of system failure. At the same time, TPS mass is carried for the entire mission duration prior to entry, and any excess TPS mass is at the cost of science payload. Future missions will benefit enormously from TPS options with mass and performance benefits far beyond advanced carbon-carbon (ACC) that is currently proposed for the DAVINCI mission. NASA STMD, and SMD jointly invested in the development of 3-D woven thermal protection systems in the last decade, and as a result, the Heat-shield for Extreme Entry Environment Technology (HEEET) TPS has been matured to TRL 6. It is ready for future mission use including Venus. The HEEET project focused on developing a broad technology base, applicable for missions not only to Venus, but also to Saturn, the Ice Giants, and higher speed sample return missions such as Mars Sample Return requiring extreme robustness due to bio-hazards. The dual-layer HEEET (DL-HEEET) is proven to be extremely robust. DL-HEEET performed well in arc jet and laser testing conditions where heritage carbon-phenolic failed. HEEET also proved to be more mass efficient compared to Carbon-Phenolic. Recently, the principal author was invited to present his perspectives to the 2023-2032 Planetary Sciences Decadal Venus subcommittee on the current state of TPS for future Venus missions [1]. In addition to pointing out successful TPS and other developments in the last decade in support of entry systems, the principal author made two findings: 1) importance of and need to sustain TPS capabilities that took nearly a decade to develop and 2) the opportunity to further optimize TPS mass without sacrificing robustness to further enable future in-situ missions. This talk will focus on the above two recommendations and provide the rationale for them. The intent of the talk is to seek advocacy from the VEXAG community for the criticality of TPS sustainment and the benefits of 3D woven TPS optimization. TPS Capability Sustainment: HEEET development was necessitated by the atrophy of heritage carbon-phenolic. Atrophy has impacted other TPS materials as well. Avcoat, the TPS that successfully allowed astronauts to explore the Moon in the 1960s and 70s, took nearly a decade and $10’sM to recover in support of Orion/Artemis. One of the most used TPS materials, SLA 561V, had to be recovered prior to its use on Mars Pathfinder. Phenolic Impregnated Carbon Ablator (PICA), the TPS that replaced SLA 561V on MSL, has undergone multiple replacements and recovery due to constituent rayon changes. Recently, NASA invested in a domestic rayon replacement program and also invested in FMI to consolidate PICA capability for NASA missions, as a result of FMI’s decision to discontinue commercial FiberForm, which is needed for PICA. TPS used for planetary missions are unique and have no other commercial or defense use. In addition, low mission cadence is also a driver for TPS atrophy. Hence, NASA, as the steward, must take steps to ensure and sustain TPS capabilities. In this talk, we outline steps NASA can take to keep abreast of emerging risks and target risk mitigation steps to ensure TPS capability sustainment for Venus and other extreme environment missions. Next Generation of Mass efficient and Robust TPS: NASA invested in an alternate TPS to PICA based on felt-technology called Conformal-PICA which has the potential to save 30% - 50% mass over PICA. The development was discontinued at a Technology Readiness Level (TRL) of ~ 5. 3D Mid-Density Carbon Phenolic (3MDCP) is a single layer variant of HEEET, based on the insulating layer only (SL-HEEET) and currently baselined for the Mars Sample Return Mission Earth Entry System due to its mass efficiency (30% more mass efficient than DL- HEEET). Currently, SL-HEEET is limited to aeroshell diameters of < 1.3m. The SL-HEEET was compared to DL-HEEET in the recent ADVENT flag-ship class mission study in support of the Planetary Science Decadal. SL HEEET was the recommended TPS based on 30% mass savings for both the balloon and lander missions. Given C-PICA and SL-HEEET have superior reliability and mass efficiency, advocacy from VEXAG is sought for completing their further development to TRL 5/6 in this decade so as to enable TPS readiness for future missions.

Thermal Protection Systems↗

DOE OSTI2016

The formation of quantum images and their transformation and super-resolution reading

Images formed by light with suppressed photon fluctuations are interesting objects for studies with the aim of increasing their limiting information capacity and quality. This light in the sub-Poisson state can be prepared in a resonator filled with a medium with Kerr nonlinearity, in which self-phase modulation takes place. Spatially and temporally multimode light beams are studied and the production of spatial frequency spectra of suppressed photon fluctuations is described. The efficient operation regimes of the system are found. A particular schematic solution is described, which allows one to realize the potential possibilities laid in the formation of the squeezed states of light to a maximum degree during self-phase modulation in a resonator for the maximal suppression of amplitude quantum noises upon two-dimensional imaging. The efficiency of using light with suppressed quantum fluctuations for computer image processing is studied. An algorithm is described for interpreting measurements for increasing the resolution with respect to the geometrical resolution. A mathematical model that characterizes the measurement scheme is constructed and the problem of the image reconstruction is solved. The algorithm for the interpretation of images is verified. Conditions are found for the efficient application of sub-Poisson light for super-resolution imaging. It is found that the image should have a low contrast and be maximally transparent.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗