Search NASA⌕ Search

SEARCH · Search NASA

Results for “Design for reliability”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Benchmarking Monte Carlo codes for the modelling of low-energy neutron production target reactions

The increasing adoption of accelerator-based neutron sources (ABNS) for applications including neutron capture therapy (NCT) research has highlighted the need for accurate simulation tools. Precise modelling of the neutron production target is crucial to ensure that simulated predictions of neutron beam characteristics used for subsequent beam shaping assembly design are reliable. This work presents a comprehensive benchmarking of four widely-used Monte Carlo codes - Geant4, PHITS, FLUKA (CERN), and MCNP - for modelling low-energy neutron production target reactions. Using their recommended physics models and cross-section libraries, we evaluate each code’s performance in simulating four beam-target reactions: 7 Li(p,n) 7 Be, 9 Be(p,n) 9 B, 9 Be(d,n) 10 B, and C(d,n)N. Predictions of neutron yield, angular distributions, and energy spectra are compared against available thick target experimental data. Results show varying levels of agreement between the codes depending on the reaction type, energy range, and beam characteristics. Geant4, MCNP and PHITS are the overall best performing codes for the simulation of total neutron yield and yield in the forward direction across most reactions. Across energies where experimental benchmarks exist, inter-code discrepancies in total and forward-directed yield are typically 10 to 30%, with larger deviations at near-threshold incident ion energies. PHITS provides the best overall reproduction of experimental spectra, particularly for the 9 Be(p,n) 9 B reaction. Additionally, PHITS demonstrates superior computational performance for most reactions. These findings provide valuable guidance for ABNS design, highlighting the strengths and limitations of each code for the simulation of low-energy neutron production reactions.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Comparative investigations of multi-fidelity modeling on performance of electrostatically-actuated cracked micro-beams

Silicon is a commonly used material for the fabrication of beams for use in micro-electrical-mechanical systems (MEMS). Although silicon is a brittle material, it has been shown to accumulate fatigue damage at the micro-scale. Understanding the effect this has on the overall device performance is critical to the design of reliable devices. Analytical methods for modeling damage provide expedient results but are limited by broad modeling assumptions. Numerical models account for more detailed physical phenomena but can be computationally intensive. In this work, two different crack scenarios are modeled using both analytical techniques and 3D computational simulations. First, the effects of a single surface crack on the static deflection and natural frequency of an electrostatically actuated micro-beam are formulated and compared. Then, a new method for approximating damage associated with realistic distributed crack networks is formulated for use in an analytical model and numerical simulations. A method for utilizing experimentally derived crack statistics to inform the analytical and numerical distributed crack models is developed. Good agreement between the analytical and numerical models is obtained for both crack scenarios. Altogether, these models can be used to effectively simulate a variety of damage and fatigue behaviors in silicon-based MEMS devices.

42 ENGINEERING↗
DOE OSTI2023

Tuning Film Stresses for Open-Air Processing of Stable Metal Halide Perovskites

Challenges to upscaling metal halide perovskites (MHPs) include mechanical film stresses that accelerate degradation, dominate at the module scale, and can lead to delamination or fracture. In this work, we demonstrate open-air blade coating of single-step coated perovskite as a scalable method to control residual film stress after processing and introduce beneficial compression in the thin film with the use of polymer additives such as gellan gum and corn starch. The optoelectronic properties of MHP films with compression are improved with higher photoluminescence yields. MHP film stability is significantly improved under compression, under humidity, heat, and thermal cycling. By measuring the evolution of film stresses, we demonstrate for the first time that stress relaxation occurs in MHP films with tensile stress that correlates with film degradation. Finally, this discovery of a new mechanism underpinning MHP degradation shows that film stress can be used as a parameter to screen MHP devices and modules for quality control before deployment as a design for reliability criterion.

14 SOLAR ENERGY↗
DOE OSTI2024

Permeability and Induced Polarization of Mudstones

Electrical measurements can be used to estimate hydraulic properties such as permeability ( k ) in sedimentary rocks. Previous work has focused on sandstones, siltstones, and carbonates, while investigations on mudstones have rarely been reported. In this study, we report on electrical geophysical measurements for 23 mudstone samples using an experimental approach designed to reliably saturate these low permeability mudstones. The modified Hagen-Poiseuille model linking permeability to the formation factor ( F ) and an effective pore radius ( r ) provides an excellent fit to the data set with a near-constant pore radius, indicating that the effective porosity (1/ F ) is the controlling factor on k . In these samples, the surface area normalized to pore volume ( S por ), frequently used in permeability estimation models, varies by 1–2 orders of magnitude and is thus not a reliable proxy of the inverse effective hydraulic radius. The formation factor also exerts the primary control on induced polarization (IP) parameters, whereas Spor shows no relation to the IP parameters. A strong linear relationship is found between IP parameters (imaginary conductivity and normalized chargeability) and surface conductivity, although the proportionality factor is significantly lower than those observed in more permeable rocks and sediments. Apparent relationships between the polarization strength-derived and time constant-derived geophysical length scales and the effective hydraulic radius appear to be driven by variations in the electrochemical parameters (i.e., specific polarizability and diffusion coefficient). Overall, these findings emphasize that predicting hydraulic properties from electrical measurements in fine-grained rocks remains challenging and requires further investigation into the electrochemical properties involved.

58 GEOSCIENCES↗
DOE OSTI2022

Forward-Looking State-of-the-Art Review on Earned Value Management Systems: The Disconnect between Academia and Industry

Earned value management (EVM) is a project management approach that can enhance the probability of project success. It is applied widely across different industry sectors (e.g., energy, aerospace, construction, defense, and manufacturing), generally through the use of an earned value management system (EVMS). A holistic and up-to-date literature review on EVM and EVMS does not exist. A literature review can provide a comprehensive perspective on the topic, identifying and summarizing the existing body of knowledge, as a foundation to advance the state of practice of EVM/EVMS. Therefore, the objective of this paper is to investigate the EVM/EVMS state of the art by critically reviewing academic and industry publications, with a specific focus on the maturity of EVMS and the environment surrounding its implementation. By performing a systematic literature review, the authors identified 600 publications since the inception of the EVM concept in 1962, and then narrowed down this list to 160 relevant publications from the last decade for closer review. The findings include the discovery of eight emergent themes. Of these themes, “forecasting/prediction” constitutes the largest portion of the recent literature, followed by “application of EVMS.” One interesting finding is that EVMS maturity, although being a critical topic, is only discussed in one publication. Publications focused on EVM/EVMS have increased in the last decade and significant differences were found between academia and industry literature in terms of the limitations and extensions of EVM/EVMS, EVMS environment, and compliance. A key finding is that designing a reliable EVMS should combine both technical and social aspects of implementation. This forward-looking paper provides a state-of-the-art review while highlighting gaps in the existing EVM/EVMS body of knowledge and introducing new perspectives to support EVMS research and application.

42 ENGINEERING↗
DOE OSTI2022

Understanding the electromagnetic topology during the ohmic breakdown in tokamaks considering self-generated electric fields

We report that the physical mechanisms of the ohmic breakdown in a tokamak have been understood based on the classical Townsend avalanche theory. However, a new systematic theory (Yoo et al 2018 Nat. Commun.9 3523) recently demonstrated that electron avalanches during the ohmic breakdown are completely different from the Townsend avalanche due to strong self-generated electric fields. In this study, we elucidate the multi-dimensional effects of the self-generated electric field on plasma dynamics during the ohmic breakdown. We also propose a novel electromagnetic topology analysis method that can easily predict the overall plasma behavior and where the main plasma is generated. The topology analysis method is validated by a state-of-art particle simulation for various magnetic configurations. New physical insights into the complex electromagnetic topology would facilitate designing more reliable and optimized ohmic breakdown scenarios in future tokamaks, such as ITER and beyond.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Nanomechanical and Fluorescence Characterizations of Weathered PV Module Encapsulation

Nanoindentation and fluorescence spectroscopy provide spatially resolved mechanical and chemical characterization for degradation of poly (ethylene-co-vinyl acetate) (EVA) encapsulants aged under accelerated weathering and in field deployed photovoltaic (PV) modules. For the accelerated weathering tests, two different EVA formulations in the glass/EVA/glass-laminated coupons were exposed to ultraviolet (UV) light for 180 days at three different temperatures (40, 60, and 80 °C) and UV intensities (0.4, 2.2, and 2.9 W/m2/nm at 340 nm). The fluorescence spectra and moduli were uniform through the cross section of both EVA formulations at the lowest temperature and UV intensity; however, under the highest temperature and UV intensity, the UV irradiated sides showed lower moduli and higher fluorescence compared to the opposite sides. For EVA obtained from PV modules deployed 27 years in Sacramento, CA, USA, changes in fluorescence intensity across the thickness were relatively greater than changes in modulus. On the other hand, for EVA obtained from the same type of module stored in the shed for 27 years, no fluorescence was observed, and a uniform modulus was seen through the EVA layer, but with substantially higher values than those obtained from the field-deployed modules. The different extent of changes between laboratory and field exposures suggests the importance of considering effects of temperature and UV intensity for designing a reliable accelerated testing. This study uniquely demonstrates the capability of microscale characterization using nanoindentation and fluorescence microscopy to monitor mechanical and chemical degradation of EVA encapsulants in PV modules.

14 SOLAR ENERGY↗
DOE OSTI2022

Instrumented Photovoltaic Modules for Environmental Characterization and Simulation Model Validation

Photovoltaic modules are subjected to various mechanical stressors in their deployment environments, ranging from installation handling to wind and snow loads. Damage incurred during these mechanical events has the potential to initiate subsequent degradation mechanisms, reducing useful module lifespan. Thus, characterizing the mechanical state of photovoltaic modules is pertinent to the development of reliable packaging designs. In this work, photovoltaic modules with strain gauges directly incorporated into the module laminate were fabricated and subjected to mechanical loading to characterize internal strains within the module when under load. These experimental measurements were then compared against results obtained by high-fidelity finite-element simulations. The simulation results showed reasonable agreement in the strain values over time; however, there were large discrepancies in the magnitudes of these strains. Both the instrumentation technique and the finite-element simulations have areas where they can improve. These areas of improvement have been documented. Despite the observed discrepancies between the experimental and simulated results, the module instrumentation proved to be a useful gauge in monitoring and characterizing the mechanical state. With some process improvements, this method could potentially be applied to other environments that a photovoltaic module will encounter in its lifetime that are known to cause damage and degrade performance.

14 SOLAR ENERGY↗
DOE OSTI2025

Solar Decarbonization of Paraffin Dehydrogenation Through Particle Heat Carriers (Final Technical Report)

This project focuses on solutions to decarbonize high-temperature catalytic processes using solar thermal heat. The primary project goal is to show the validity of a moving packed bed reactor for propane dehydrogenation using catalyst particles as the heat carrier for the reaction, which can be heated by concentrated solar energy in a particle receiver. This concept, if further developed, may provide a cost-effective pathway for converting lower value gases to important chemical precursors for industrial materials using only renewable energy. The project was divided into six tasks. In Task 1, DFT calculations were performed to understand the role of Pt and Sn in the catalytic dehydrogenation reaction. In Task 2 chemical kinetics measurements were made for several catalyst formulations at high temperatures. In Task 3, the solar absorptance of catalyst particles was compared to the absorptance of commonly used materials in particle receivers. In Task 4, numerical models were developed which could predict performance of the complete system and predict specific temperatures in the system. In Task 5, a prototype system was designed, fabricated, and tested to show the validity of the concept. Task 6 concerned project management activities. Experiments with the prototype showed repeatable thermal performance at temperatures targeted for the reaction. A limited set of tests were done with active catalyst and propane dehydrogenation, showing conversion of propane to propylene with a range of conversions and selectivities. The results are promising, and the prototype designed was reliable during testing, and the team expects that further development of the prototype would yield improved results. A numerical model framework based on coupled fluid and particle mechanics was developed with high computational efficiency using GPU calculations. The model may prove highly useful for evaluating other high-temperature particle systems. However, it was determined that simpler porous media models were good fits for the needs of the current moving packed bed concept. Data showing strong solar absorption of the particles validates the plan of using existing solar particle receivers with only a change in the particle type. Catalyst investigation showed that Pt 1 Sn 3 is the most viable candidate for developing PtSn catalysts for high temperature propane dehydrogenation, considering the balance of activity, selectivity, and deactivation. This project completed an initial study of various factors needed to incorporate a moving bed catalytic reactor for propane dehydrogenation into a concentrated solar thermal particle system. Future developments may allow this technology to be scaled up and help to use solar thermal energy to decarbonize not only the propane dehydrogenation reaction, but other gas-solid catalytic reactions at similar temperatures.

14 SOLAR ENERGY↗
DOE OSTI2026

BIL GRID-READY WIND: Reliable and Economical Grid Services Design, Implementation, and Demonstration at the Great Pathfinder Wind Power Plant

The GRID-READY WIND project aimed to demonstrate the ability of utility-scale wind power plants (WPPs) to deliver traditional and emerging grid services (GSs) in both grid-following (GFL) and grid-forming (GFM) modes through a centralized control framework, supplemented by local control adjustments at the wind turbine generator as needed. Throughout the project, the team offered recommendations on how the grid services demonstrated with WPPs could be applied to other inverter-based resources (IBRs), such as photovoltaic (PV) systems and battery energy storage systems (BESS), while considering the unique dynamics of these resources arising from their energy generation characteristics. The project sought to enhance the confidence of system operators (SOs) and planners in utilizing WPPs, alongside other IBRs such as PV plants and BESS, to provide essential grid services over extended periods under diverse operating conditions, thereby supporting their integration into the bulk power system.

17 WIND ENERGY↗
DOE OSTI2022

Modeling Needs for High Power Target

The next generation of high power targets will use more complex geometries, novel materials, and new concepts (like flowing granular materials); however, the current numerical approaches will not be sufficient to converge towards a reliable target design that satisfies the physical requirements. We will discuss what can be improved in the next 10 years in target modeling to support high power (MW class) targets.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

ASME – Grappling with the Concept of Component Failure

ASME concepts of component failure. Definition for failure, functionality, damage tolerance, including Magnox reactors and AGRs. How ASME is addressing damage tolerance, and Section III division 5 Design, Classification, Reliability Target for SRC-1 components, Basic analysis approach, simple assessment, and full assessments, Reference to reliability and integrity management and strategy for graphite components.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Simulating Alpha Particles Incident on MKID Chips for Quantum Sensitivity Analysis

Superconducting quantum devices, such as microwave kinetic inductance detectors (MKIDs), are highly sensitive instruments used in quantum computing and advanced sensing technologies. However, their extreme sensitivity also makes them vulnerable to background noise from natural sources like radiation. One significant contributor to this noise is alpha particles emitted by 210Po, a radon decay daughter that accumulates on surfaces near the detector. This project investigates how alpha particles emitted from 210Po interact with MKID chips. These particles can deposit energy on the detector surface, disrupting its operation and generating false signals. Understanding the energy and behavior of these particles is crucial for improving the design and reliability of quantum devices. To explore this, we first modeled the decay chain starting from 210Pb to 210Po using differential equations. This allowed us to predict how the activity of alpha-emitting isotopes changes over time, reaching a steady state after about two years. Next, we simulated alpha particle interactions with the MKID chip using the Geant4 software toolkit. We built a detailed computer model of the detector housing, including the copper lid where alpha particles originate, the silicon chip, and a thin aluminum sensor layer. Alpha particles were emitted isotropically from just beneath the copper lid’s surface, mimicking natural decay conditions. The simulation tracked how these particles deposit energy on the chip, generating electron-hole pairs and phonons. The results provide insight into the behavior of the resultant electron-hole pairs and phonons, giving us a clear understanding of the energy deposition distribution on the chip. This work supports efforts to mitigate background noise in superconducting sensors, advancing their use in quantum computing and sensitive physics experiments.

Hall, Matthew [Fermilab; UCLA]↗
DOE OSTI2023

Integrated Sustainable Product Design With Warranty and End-of-Use Considerations

The concept of integrated sustainable product design has recently emerged, aiming to incorporate downstream life cycle performance into the initial product design to enhance sustainability. Various sustainable product design tools based on life cycle assessment or quality function deployment have been established while the impact of reliability on circular practices has received limited attention. Recognizing the critical role of product reliability in post-design performance, this paper develops a product design optimization model that considers the warranty performance and the effect of end-of-use options. The model takes into account the effect of uncertain operating conditions on product reliability. Two optimization goals including the minimization of expected unit life cycle cost and environmental impact are achieved by the model. To demonstrate the benefits of the integrated approach, the model is applied to an electric motor design problem. The results highlight that integrating end-of-use options in the early design phase leads to adjustments in component selection and reliability design. Moreover, the circular utilization of used products enables cost savings throughout the product’s life cycle and contributes to environmental impact reduction. Finally, the study analyzes the effects of operating conditions, warranty policies, and take-back prices for used products on design decisions, providing valuable insights for product designers.

Integrated design↗
DOE OSTI2024

Sensitivity of fatigue reliability in wind turbines: effects of design turbulence and the Wöhler exponent

Fatigue assessment of wind turbines involves three main sources of uncertainty: material resistance, load, and the damage accumulation model. Many studies focus on increasing the accuracy of fatigue load assessment to improve the fatigue reliability. Probabilistic modeling of the wind's turbulence standard deviation is an example of an approach used for this purpose. Editions 3 and 4 of the IEC standard for the design of wind energy generation systems (IEC 61400-1) suggest different probability distributions as alternatives for the representative turbulence in the normal turbulence model (NTM) of edition 1. There are debates on whether the suggested distributions provide conservative reliability levels, as the established design safety factors are calibrated based on the representative turbulence approach. The current study addresses the debate by comparing annual reliability based on different scenarios of NTM using a probabilistic approach. More importantly, it elaborates on the relative importance of load assessment accuracy in defining the fatigue reliability. Using the DTU 10 MW reference wind turbine and the first-order reliability method (FORM), we study the changes in the annual reliability level and its sensitivity to the three main random inputs. We perform the study considering the blade root flapwise and the tower base fore–aft moments, assuming different fatigue exponents in each load channel. The results show that integration over distributions of turbulence in each mean wind speed results in less conservative annual reliability levels than representative turbulence. The difference in the reliability levels varies according to turbulence distribution and the fatigue exponent. In the case of the tower base, the difference in the annual reliability index after 20 years can be up to 50 %. However, the model and material uncertainty have much higher effects on the reliability levels compared to load uncertainty. Knowledge about such differences in the reliability levels due to the choice of turbulence distribution is especially important, as it impacts the extent of lifetime extension through reliability reassessments.

17 WIND ENERGY↗
DOE OSTI2025

Neutron irradiation & thermomechanical experiment (NITE) - design

For the reliable long-term operation of fusion power plants, it is crucial to understand and predict the lifetime of materials in use. These materials include all structural and functional materials utilized at the first wall, blanket, magnets, and shielding. The key challenge is, that the harsh environment including high heat fluxes, high thermal stress and stress cycling, neutron irradiation, and sputtering on such materials should not be viewed separately. Currently, the synergistic loads cannot be evaluated experimentally because of the lack of adequate facilities. The purpose of that work is to design a synergetic Neutron Irradiation and Thermomechanical Experiment (NITE) for fusion materials. This design will leverage the existing Advanced-Test-Reactor (ATR), a fission reactor at the Idaho National Laboratory. We also acknowledge that with existing fission reactors the exact fusion condition cannot be created, and the limitations are critically discussed. The combination of neutron irradiation with a high heat flux is the focus. This is realized with an irradiation capsule design that includes a TRISO fueled region inside the capsule to enable a steady-state heat flux on one side of the specimen. In conclusion, the experimental design modeling showed that steady-state heat fluxes of 2.4 MW/m 2 with a thermal gradient of above 250°C can be achieved in a 5 mm thick specimen.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗