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DOE OSTI2023

Main Bearing Replacement and Damage - A Field Data Study on 15 Gigawatts of Wind Energy Capacity

This study seeks to establish a comprehensive baseline of knowledge for the replacement and damage of main bearings in wind turbines. The purpose of this report is to provide a high-level summary of the data set, methodology, and results of this work. Full technical details and an extended analysis will be made available in a future publication. We collected data on main bearing replacements and reported damage from industrial partners based in Europe and the United States. In total, we obtained data for 167 wind power plants, with a combined capacity of 15.3 gigawatts (GW). Most of the data set was comprised of land-based, three-point mount, spherical roller bearings. Within this data set were 689 instances of main bearing replacement. Analysis was undertaken in two parts: first, a statistical analysis of the main bearing time-to-replacement data using survival analysis techniques; second, quantitative and qualitative analyses of the obtained damage information. Our results showed that 10% of a fixed main bearing population would be expected to have been replaced by 10.5 years. This is close to half of the 20-year design value. Fitted parametric distributions then indicated that by year 20, between 22% and 25% of main bearings are expected to have been replaced. Analysis of the damage reports revealed spalling to be the main type of damage listed. The additional presence of surface damage in the collected data indicates that at least part of the spalling cases are likely due to surface-initiated rolling contact fatigue. At this stage is not clear what proportion of spalling cases result from "wear induced", surface-initiated and subsurface-initiated rolling contact fatigue. While this work provides important insights into the current state of main bearing replacements and damage, many questions remain. An ongoing and expanding data collection and analysis effort focused on wind turbine main bearings is therefore recommended.

17 WIND ENERGY↗

DOE OSTI2020

Three dimensional radioisotope battery and methods of making the same

According to one embodiment, a product includes an array of three dimensional structures, where each of the three dimensional structure includes a semiconductor material; a cavity region between each of the three dimensional structures; and a first material in contact with at least one surface of each of the three dimensional structures, where the first material is configured to provide high energy particle and/or ray emissions.

07 ISOTOPE AND RADIATION SOURCES↗

NASA NTRS1991

A fast implicit upwind solution algorithm for three-dimensional unstructured dynamic meshes

A fast implicit upwind algorithm for the solution of the time-dependent Euler equations is presented for aerodynamic analysis involving unstructured dynamic meshes. The spatial discretization of the scheme is based on the upwind approach of Roe, referred to as flux-difference splitting (FDS). The FDS approach is naturally dissipative and captures shock waves and contact discontinuities sharply. The temporal discretization of the scheme involves an implicit time-integration using a two-sweep Gauss-Seidel relaxation procedure. The procedure is computationally efficient for either steady or unsteady flow problems. A detailed description is given of the implicit upwind solution algorithm along with results which assess the capability. The results are presented for the NACA 0012 airfoil and for the Boeing 747 aircraft. The 747 geometry includes the fuselage, wing, horizontal and vertical tails, under-wing pylons, and flow-through engine nacelles. Euler solutions for the 747 aircraft on an unstructured tetrahedral mesh containing approximately 100,000 cells were obtained to engineering accuracy in less than one hour CPU time on a Cray-2 computer.

Batina, John T.↗

NASA NTRS1992

A fast implicit upwind solution algorithm for three-dimensional unstructured dynamic meshes

Batina, John T.↗

NASA NTRS2006

Development of Analytical Protocols For Organics and Isotopes Analysis on the 2009 MARS Science Laboratory.

The Mars Science Laboratory, under development for launch in 2009, is designed explore and quantitatively asses a local region on Mars as a potential habitat for present or past life. Its ambitious goals are to (1) assess the past or present biological potential of the target environment, (2) to characterize the geology and geochemistry at the MSL landing site, and (3) to investigate planetary processes that influence habitability. The planned capabilities of the rover payload will enable a comprehensive search for organic molecules, a determination of definitive mineralogy of sampled rocks and fines, chemical and isotopic analysis of both atmospheric and solid samples, and precision isotope measurements of several volatile elements. A range of contact and remote surface and subsurface survey tools will establish context for these measurements and will facilitate sample identification and selection. The Sample Analysis at Mars (SAM) suite of MSL addresses several of the mission's core measurement goals. It includes a gas chromatograph, a mass spectrometer, and a tunable laser spectrometer. These instruments will be designed to analyze either atmospheric samples or gases extracted from solid phase samples such as rocks and fines. We will describe the range of measurement protocols under development and study by the SAM engineering and science teams for use on the surface of Mars.

Mahaffy, P. R.↗

DOE OSTI2021

Deployment of salt sample extraction system at an engineering-scale electrorefiner

The goal of the salt sampling program at Argonne is to develop and deploy automated molten salt sampling approaches for interfacing relevant unit operations with salt analysis to improve the timeliness of sampling-based accountancy measurements. Two technologies under development in support of this goal are a vacuum sampling loop module and a high-throughput pneumatic sample generator module. Compared to traditional point sampling approaches (i.e., dip probes), the vacuum sampling loop facilitates the collection of a larger cross-section of the bulk salt in order to collect more representative samples. The vacuum sampling approach also eliminates the risk of dross contamination of samples and avoids the use of moving parts in the salt. The pneumatic sample generator module is used to facilitate high-throughput sample analysis to improve the measurement precision of any given analytical technique by averaging out random sampling and measurement errors. In FY21, two methods for integrating these two modules were tested including direct fluidic coupling and coupling using a solid salt transfer mechanism. Solid salt transfer was ultimately selected over fluidic coupling, primarily to enable the transport of samples over longer distances to support automated at-line integration with high-precision techniques (such as microcalorimetry) that cannot withstand the conditions near an electrorefining process. To facilitate rapid solid salt coupling, new mechanisms were developed for rapidly charging and discharging salt sample tubes at the vacuum sampling loop and pneumatic sample generator modules, respectively. While the charging mechanism will be deployed in FY22, the discharge mechanism was tested in FY21 and is described here. The solid salt tube transfer method was deployed at one of Argonne’s engineering-scale electrorefiners to implement at-line high-throughput pneumatic micro-sample generation capabilities. The approach was used to generate precise uranium- and lanthanide-bearing electrorefiner micro-samples with the specific dimensions requested by researchers at Los Alamos National Laboratory for use in testing their novel microcalorimeter x-ray techniques. The solid salt transfer mechanism proved not only to be an effective means of integrating the precision sample generator with vacuum sampling, but also improved the performance of the sampler generator. To discharge salt from the sample tubes at the sampler generator, tube segments were inserted directly into the sample generator’s Helmholtz chamber and pressure pulse actuations were used to generate precision molten salt samples directly from the tube segments. The direct insertion of sample tubes into the sample generator enabled rapid loading of the salt and prevented salt from contacting most of the interior surfaces of the sample generator, which eliminated cross-contamination between runs. The vacuum sampling-loop tube charging mechanism will support high-throughput tube sampling operations by employing a dynamic vacuum filling process to fill short charge tubes that are configured to be rapidly connected and disconnected from the loop. The dynamic vacuum sampling operation will be automated, and sample tube handling can be executed with simple overhead actuation. Because the modular sampling approach described here eliminates the need for new high-radiation sample handling capabilities, salt-wetted seals, salt-wetted moving parts, and heated transfer lines outside the electrorefiner, it will address most of the remaining technical challenges for the at-line deployment of high-precision analytical techniques which will enable significant reductions in the time delay for sampling-based high-precision accountancy measurements.

42 ENGINEERING↗

DOE OSTI2026

Engineering Microstructure in Dry-Processed Cathodes Via Calendering

Calendering serves as a multifunctional step in dry electrode processing that not only densifies the electrode but also induces polytetrafluoroethylene (PTFE) fibrillation and reorganizes the microstructure. These coupled effects are essential for achieving electrical connectivity and sufficient cohesion, yet they also introduce trade-offs, such as active material particle fracture, pore collapse, and excessive porosity loss, that can hinder ionic transport. This research systematically maps the calendering parameter space for LiNi0.6Mn0.2Co0.2O2 (NMC622) dry cathodes with a target thickness of ∼100 µm and porosity of ∼30% by varying roll gaps, roll temperature, roll speed, and the number of passes. A practical processing window for this formulation and electrode architecture is identified that achieves sufficient PTFE fibrillation and strong interfacial contact while minimizing particle fracture and preserving the porosity required for efficient ionic transport. In particular, gradual-gap calendering with moderate per-pass compression mitigates fracture and pore collapse while still reaching the target thickness with reasonable throughput, and slower roll speeds with modest roll temperatures further reduce mechanical damage. These results provide actionable guidance for scaling NMC622-based thick dry-processed cathodes.

Park, Hyunji↗

DOE OSTI2024

Transient Chemo‐Mechanical Model of Lithium Plating Impacted by External Pressure

Abstract Lithium anodes show great promise in commercial applications, but are hindered by lithium plating and dendrite growth which cause safety concerns during long‐term cell operation. Stack pressure is experimentally observed to improve cell lifetime; however, the relationship between stress and lithium deposition has remained difficult to elucidate. In this work, a transient, 3D, finite‐element model of the evolution of a lithium anode due to stripping and plating is developed. The evolution of a microscale protrusion on the anode surface is tracked over one charge‐discharge cycle with respect to stack pressure and lithium yield strength. Lithium plastic deformation, nonconformal anode‐separator contact, and separator porosity effects are accounted for. Over the course of several hours of stripping/plating, the anode surface evolves to a similar morphology under pressure regardless of the initial conditions due to lithium plastic deformation and hardening. The rate of this evolution highly depends on the applied pressure and assumed lithium yield strength.

25 ENERGY STORAGE↗

DOE OSTI2020

An interface-aware sub-scale dynamics multi-material cell model for solids with void closure and opening at all speeds

Here, we present a multi-material cell model (closure model) for demanding arbitrary Lagrangian-Eulerian (ALE) simulations of fluids and solids. It is based on the interface-aware sub-scale dynamics (IASSD) approach which utilizes the exact material interface geometry within the computational cell to calculate internal material interactions. Our formulation of the closure model also aims to improve the accuracy in low-speed impact events. Voids are used to represent ambient vacuum and internal free boundaries of the distinct materials. Void regions can close and open at contact surfaces, allowing a transition from contact physics to free motion in vacuum. The coupling of void closure and opening with a new formulation of the IASSD model for solids is tested on several one- and two-dimensional numerical examples, ranging from gas expansion in vacuum to planar and round object impacts at various speeds.

42 ENGINEERING↗

DOE OSTI2020

Stretchable electrochemical energy storage devices

The increasingly intimate contact between electronics and the human body necessitates the development of stretchable energy storage devices that can conform and adapt to the skin. Therefore, the development of stretchable batteries and supercapacitors has received significant attention in recent years. This review provides an overview of the general operating principles of batteries and supercapacitors and the requirements to make these devices stretchable. The following sections provide an in-depth analysis of different strategies to convert the conventionally rigid electrochemical energy storage materials into stretchable form factors. Namely, the strategies of strain engineering, rigid island geometry, fiber-like geometry, and intrinsic stretchability are discussed. A wide range of materials are covered for each strategy, including polymers, metals, and ceramics. By comparing the achieved electrochemical performance and strain capability of these different materials strategies, we allow for a side-by-side comparison of the most promising strategies for enabling stretchable electrochemical energy storage. The final section consists of an outlook for future developments and challenges for stretchable supercapacitors and batteries.

25 ENERGY STORAGE↗

DOE OSTI2022

Demonstration of Spectral Selectivity of Efficient and Ultrafast GaN/AlGaN-Based Metal–Semiconductor–Metal Ultraviolet Photodiodes

Efficient and ultrafast (aluminum)-gallium-nitride-based metal-semiconductor-metal (Al x )Ga 1–x N ultraviolet photodiodes were implemented to investigate the spectral properties of GaN/AlGaN-based photodetectors. Al composition of the GaN templates were varied from 0-% to 30% to demonstrate the impact of Al mole fraction on the cutoff wavelength of these UV photodiodes. Asymmetric metal contact electrodes were fabricated to optimize the external quantum efficiency without compromising their ultrafast photoresponse. Here, the best performing devices exhibited a peak response of 4 V and an oscilloscope limited temporal pulse width of 61 ps at a 20-V bias with a peak spectral responsivity of 36.5 mA/W at 280 nm.

42 ENGINEERING↗

DOE OSTI2020

Water Structure and Properties at Hydrophilic and Hydrophobic Surfaces

The properties of water on both molecular and macroscopic surfaces critically influence a wide range of physical behaviors, with applications spanning from membrane science to catalysis to protein engineering. Yet, our current understanding of water interfacing molecular and material surfaces is incomplete, in part because measurement of water structure and molecular-scale properties challenges even the most advanced experimental characterization techniques and computational approaches. This review highlights progress in the ongoing development of tools working to answer fundamental questions on the principles that govern the interactions between water and surfaces. One outstanding and critical question is what universal molecular signatures capture the hydrophobicity of different surfaces in an operationally meaningful way, since traditional macroscopic hydrophobicity measures like contact angles fail to capture even basic properties of molecular or extended surfaces with any heterogeneity at the nanometer length scale. Resolving this grand challenge will require close interactions between state-of-the-art experiments, simulations, and theory, spanning research groups and using agreed-upon model systems, to synthesize an integrated knowledge of solvation water structure, dynamics, and thermodynamics.

catalysis (heterogeneous)↗

DOE OSTI2019

Enhancement of EM Pump Performance through Modeling and Testing

Liquid sodium has seen development as a nuclear reactor coolant in the United States for over 50 years. While sodium has many desirable characteristics as a heat transfer fluid, its reactivity poses numerous engineering challenges for even the most basic plant components like pumps. Despite the challenges, mechanical pumps have seen success in sodium service albeit at the expense of simplicity and flexibility. In fact, significant failures of these pumps have been recorded which can be attributed to their complexity. Notwithstanding the complexity, mechanical pumps are still widely proposed for the main circuit pump of sodium cooled reactors. However, an alternative to mechanical pumps are Electromagnetic Induction Pumps (EMIPs) which use the principle of the Lorentz Force. EMIPs avoid mechanically moving parts in contact with sodium which simplifies the design by avoiding mechanical wear and seals. Therefore, these pumps are generally safer and more reliable than their mechanical counterparts. That being said, EMIPs suffer from relatively low efficiencies that range from 5% to 45%. Some of the inefficiencies are inherent to the EMIPs pumps; namely, inefficiencies arise in the form of resistive heating losses in the fluid itself. However, other inefficiencies arise from Edge Effects which include Finite Length and Finite Width effects. Due to the significant safety advantages EMIPs have compared to mechanical pumps, there is a strong motivation to integrate these technologies into the design of Generation IV liquid-metal-cooled nuclear power plants. However, EMIPs have low efficiencies partly attributed to Edge Effects. Much of the literature focusing on Edge Effects is dated or simply does not exist in the public domain. More recently, numerical models of EMIPs have shown promising results. However, these models are often custom solvers or use complex software suits which limit their application. This report describes the work completed to understand Edge Effects in two EMIPs designs. These designs are the Annular Linear Induction Pump (ALIP) and Permanent Magnet Induction Pump (PMIP) also known as a Moving Magnet Pump (MMP). The methodology developed during this project aim at measuring key performance parameters (pressure-flowrate and efficiency-slip performance) using high temperature liquid-sodium. Baseline experimental measurements were then used to verify the accuracy of numerical models developed in the software suit ANSYS/FLUENT. On the experimental side, instrumentation was developed to characterize the pressure-flowrate and efficiency-slip performance of both the ALIP and PMIP in high-temperature liquid-sodium. Additionally, instrumentation was developed to measure potential output pressure pulsations and the magnetic field distributions. Moreover, a specialized ALIP was constructed to study the impacts magnetic field tapering, also known as coil grading, on the Finite Length Effect. Lastly, experimental performance curves of the PMIP were collected at 300 oC and 600 oC and compared to analytical theory which accounted for Finite Width Effects. These results showed that the Finite Width Effect and non-uniform magnetic field in a PMIP impact the performance. On the numerical side, models were developed using the software suit FLUENT/ANSYS. These methods were initially compared against a simple MHD flow in a Permanent Magnet Electromagnet Flowmeter (PMEMFM). The results were significant in that they showed agreeance between the numerical model and demonstrated that PMEMFM’s could be calibrated numerically. These modeling methods were then applied to a prototypic PMIP. Results showed that this simple model provided reasonably accurate results of the PMIP p-Q performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1974

Composition surveys of test gas produced by a hydrogen-oxygen-air burner

As a result of the need for a uniform hot gas test stream for fuel injector development for hydrogen fueled supersonic combustion ramjet engines, an experimental study of injector configuration effect on exit flow uniformity of a hydrogen fueled oxygen replenished, combustion burner was made. Measurements used to investigate the burner nozzle exit profiles were pitot and gas sample measurements. Gas composition and associated temperature profiles were reduced to an acceptable level by burner injector modifications. The effect of the injector modifications was to redistribute the hydrogen fuel, increase the air pressure drop, promote premixing of the oxygen and air, and establish a uniform flow pattern where the oxygen-air mixture comes into contact with the hydrogen fuel. The most sensitive phenomenon which affected the composition profiles was the uniformity of the air distribution supplied to the combustion chamber.

Eggers, J. M.↗

NASA NTRS2001

Rocket Engine Thrust Chamber Assembly

A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel having the configuration of an assembly having a combustion chamber portion connected to a nozzle portion through a throat portion is wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The width of the tape is positioned at an angle of 30 to 50 deg. to the axis of the mandrel such that one edge of the tape contacts the mandrel while the other edge is spaced from the mandrel. The phenolic in the tape is cured and the end of the wrap is machined to provide a frusto-conical surface extending at an angle of 15 to 30 deg. with respect to the axis of the mandrel for starting a second wrap on the mandrel to cover the throat portion. The remainder of the mandrel is wrapped with a third silica tape having its width positioned at a angle of 5 to 20 deg. from the axis of the mandrel. The resin in the third tape is cured and the assembly is machined to provide a smooth outer surface. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.

Cornelius, Charles S.↗

NASA NTRS2004

Research and Technology 2003

The NASA Glenn Research Center at Lewis Field, in partnership with U.S. industries, universities, and other Government institutions, is responsible for developing critical technologies that address national priorities in aeropropulsion and space applications. Our work is focused on research for new aeropropulsion technologies, aerospace power, microgravity science (fluids and combustion), electric propulsion, and communications technologies for aeronautics, space, and aerospace applications. As NASA s premier center for aeropropulsion, aerospace power, and turbomachinery, our role is to conduct world-class research and to develop key technologies. We contribute to economic growth and national security through safe, superior, and environmentally compatible U.S. civil and military aircraft propulsion systems. Our Aerospace Power Program supports all NASA Enterprises and major programs, including the International Space Station, Advanced Space Transportation, and new initiatives in human and robotic exploration. Glenn Research Center leads NASA s research in the microgravity science disciplines of fluid physics, combustion science, and acceleration measurement. Almost every space shuttle science mission has had an experiment managed by NASA Glenn, and we have conducted a wide array of similar experiments on the International Space Station. The Glenn staff consists of over 3200 civil service employees and support service contractor personnel. Scientists and engineers comprise more than half of our workforce, with technical specialists, skilled workers, and an administrative staff supporting them. We aggressively strive for technical excellence through continuing education, increased diversity in our workforce, and continuous improvement in our management and business practices so that we can expand the boundaries of aeronautics, space, and aerospace technology. Glenn Research Center is a unique facility located in northeast Ohio. Situated on 350 acres of land adjacent to the Cleveland Hopkins International Airport, Glenn comprises more than 140 buildings, including 24 major facilities and over 500 specialized research and test facilities. Additional facilities are located at Plum Brook Station, which is about 50 miles west of Cleveland. Plum Brook Station has four large, major, world-class facilities for space research available for Government and industry programs. Knowledge is the end product of our activities. The R&T reports help make this knowledge fully available to potential users the aircraft engine industry, the space industry, the energy industry, the automotive industry, the aerospace industry, and others. It is organized so that a broad cross section of the community can readily use it. Each article begins with a short introductory paragraph that should prove valuable for the layperson. These articles summarize the progress made during the year in various technical areas and portray the technical and administrative support associated with Glenn s technology programs. We hope that this information is useful to all. If additional information is desired, readers are encouraged to contact the researchers identified at the end of each article and to visit Glenn on the World Wide Web at http://www.grc.nasa.gov.

Julian Earls↗

NASA NTRS1998

Research and Technology 1997

NASA Lewis Research Center is responsible for developing and transferring critical technologies that address national priorities in aeropropulsion and space applications in partnership with U.S. industries, universities, and Government institutions. As NASA s designated Lead Center for Aeropropulsion, our role is to develop, verify, and transfer aeropropulsion technologies to U.S. industry. As NASA s designated Center of Excellence in Turbomachinery, our role is to develop new and innovative turbomachinery technology to improve the reliability, performance, efficiency and affordability, capacity, and environmental compatibility of future aerospace vehicles. We also maintain a science and technology development role in aeropropulsion, communications, space power and onboard propulsion, and microgravity fluid physics and combustion. We are committed to enabling non-aerospace U.S. industries to benefit directly from the technologies developed through our programs to maximize the benefit to the Nation and the return on each taxpayer s investment. In addition, we are aggressively pursuing continuous improvement in our management and business practices and striving for diversity in our workforce as together we push the edge of technology in space and aeronautics. The Lewis Research Center is a unique facility located in an important geographical area, the southwest corner of Cleveland, Ohio. Situated on 350 acres of land adjacent to the Cleveland Hopkins International Airport, Lewis comprises more than 140 buildings that include 24 major facilities and over 500 specialized research and test facilities. Additional facilities are located at Plum Brook Station, which is about 50 miles west of Cleveland. Over 3700 people staff Lewis, including civil service employees and support service contractors. Over half of them are scientists and engineers, who plan, conduct or oversee, and report on our research tasks and projects. They are assisted by technical specialists, skilled workers, and an administrative staff. Our end product is knowledge. This report is designed to help us make this knowledge fully available to potential users the aircraft engine industry, the energy industry, the automotive industry, the aerospace industry, and others. It is organized so that a broad cross section of the community can readily use it. Each article begins with a short introductory paragraph that should prove to be a valuable tool for the layperson. These articles summarize the progress made during the year in various technical areas and portray the technical and administrative support associated with Lewis technology programs. We hope that the information is useful to all. If additional information is desired, readers are encouraged to contact the researchers identified in the articles and to visit Lewis on the World Wide Web (http://www.lerc.nasa.gov/). This document is available on the World Wide Web (http://www.lerc.nasa.gov/WWW/RT).

Source record↗

NASA NTRSDate not supplied

Dust Characterization Needs for Dust Mitigation

Unknowns remain regarding several lunar dust characteristics, and the lunar dust mitigation community, in collaboration with the science community, is compiling a list of lunar dust characterization needs. It is expected, through the course of currently planned or future lunar surface mission instrumentation, lab experiments, or analysis, that some of these unknowns will be characterized. This list is derived from several sources including findings from the 2020 publication “The Impact of Lunar Dust on Human Exploration”, NASA-STD-1008, SLS-SPEC-159 DSNE, and known gaps identified within NASA programs and projects. The goal of this information collection process is to create a list of dust characterization needs based on scientific and engineering knowledge gaps that will aid in the design and survival of designed and future systems, and address the challenges related to defining the lunar environment and mitigating lunar dust effects on systems and operations. Examples of dust properties and characterization needs include detailed examination of the finest fraction of lunar regolith as it varies by surface location, understanding dust transfer within natural and induced environments, determination of the effects of the lunar plasma environment with regards to materials and hardware, understand the triboelectric charging effects for activities and hardware in contact with the regolith, including grain to grain electrostatic interactions, and material adhesive properties.

dust mitigation↗