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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower (CRADA NFE-18-07280 Final Report)

ORNL worked with Cadens, LLC, to explore the use of additive manufacturing (AM) to produce low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials. Cadens also operates a micro-hydro lab to test AM components in controlled environments. Until now, Cadens’ tests have been limited to components of a size that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end-use parts of a hydropower system, using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include a draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. In addition, a runner system was fabricated using fused deposition modeling on a 3D Platform Workbench 400 Series System.

13 HYDRO ENERGY↗
DOE OSTI2024

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗
NASA NTRS2020

An Experimental Approach to a Rapid Propulsion and Aeronautics Concepts Testbed

Modern aircraft design tools have limitations for predicting complex propulsion-airframe interactions. The demand for new tools and methods addressing these limitations is high based on the many recent Distributed Electric Propulsion (DEP) Vertical Take-Off and Landing (VTOL) concepts being developed for Urban Air Mobility (UAM) markets. We propose that low cost electronics and additive manufacturing can support the conceptual design of advanced autonomy-enabled concepts, by facilitating rapid prototyping for experimentally driven design cycles. This approach has the potential to reduce complex aircraft concept development costs, minimize unique risks associated with the conceptual design, and shorten development schedule by enabling the determination of many "unknown unknowns" earlier in the design process and providing verification of the results from aircraft design tools. A modular testbed was designed and built to evaluate this rapid design-build-test approach and to support aeronautics and autonomy research targeting UAM applications utilizing a complex, transitioning-VTOL aircraft configuration. The testbed is a modular wind tunnel and flight model. The testbed airframe is approximately 80% printed, with labor required for assembly. This paper describes the design process, fabrication process, ground testing, and initial wind tunnel structural and thermal loading of a proof-of-concept aircraft, the Langley Aerodrome 8 (LA-8).

McSwain, Robert G.↗
NASA NTRS2018

CARBO - The Carbon Observatory Instrument Suite - The Next Generation of Earth Observing Instruments for Global Monitoring of Carbon Gases

The Carbon Observatory Instrument Suite, or CARBO, consists of four carbon observing instruments sharing a common instrument bus, yet targeted for a particular wavelength band each with a unique science observation. They are: a) Instrument 1, wavelength centered at 756 nm for oxygen and solar-induced chlorophyll fluorescence (SIF) observations, b) Instrument 2, centered at 1629 nm, for carbon dioxide (CO2) and methane (CH4) observation, c) Instrument 3, centered at 2062 nm for carbon dioxide and d) Instrument 4, centered at 2328 for carbon monoxide (CO) and methane. From low-Earth orbit, these instruments have a field-of-view of 10 to 15 degrees, and a spatial resolution of 2 km square. These instruments have a spectral resolving power ranging from ten to twenty thousand, and can monitor columnaverage dry air mole fraction of carbon dioxide (XCO2) at 1.5 ppm, and methane (XCH4) at 7 ppb. These new instruments will advance the use of immersion grating technology in spectrometer instruments in order to reduce the size of the instrument, while improving performance. These compact, capable instruments are envisioned to be compatible with small satellites, yet modular to be configured to address the particular science questions at hand. Here we report on the current status of the instrument design and fabrication, focusing primarily on Instruments 1 and 2. We will describe the key science and engineering requirements and the instrument performance error budget. We will discuss the optical design with particular emphasis on the immersion grating, and the advantages this new technology affords compared to previous instruments. We will also discuss the status of the focal plane array and the detector electronics and housing. Finally, we report on a new approach – developed during this instrument design process - which enables simultaneous measurement of both orthogonal polarization states (S and P) over the field-of-view and optical bandpass. We believe this polarization sensing capability will enable science observations which were previously limited by instrumental and observational degeneracies. In particular: improved sensitivity to all species, better sensitivity to surface polarization effects, better constraints on aerosol scattering parameters, and superior discrimination of the vertical distribution of gases and aerosols.

Bernas, Michael↗
DOE OSTI2024

The Design, Fabrication, and Test Program for NREL's Wave-Powered Desalination System

Starting in 2018, the U.S. Department of Energy's Water Power Technologies Office (WPTO), initiated the development of a prize competition as a foundational investment of Powering the Blue Economy, the prize encouraged the development of small, modular, cost-competitive wave-powered desalination systems. The National Renewable Energy Laboratory (NREL) was tasked with managing the prize, known as the Waves to Water Prize (W2W), and providing technical input based on prior desalination research performed at the lab. NREL partnered with the Coastal Studies Institute (CSI) and Jennette's Pier in North Carolina for their expertise in deploying research articles at the Jennette's Pier research facility. The prize consisted of five stages that included high-level concept proposals, numerical modelling, site-specific design, subsystem prototyping, and a final ocean demonstration. Due to the logistical risks of installing numerous prototypes in the ocean at the same time, NREL was tasked with designing and building a test article to de-risk the final event. The test article design needed to represent the technologies expected in the final stage of the prize. This meant that the design was expected to follow the same rules as the competitors, providing CSI with an opportunity to practice installations and develop a final logistics plan prior to the final event. After concluding the W2W event in April 2022, the NREL test article was redeployed in August 2022 to better understand the challenges of anchoring wave energy converters (WECs) in shallow water conditions with breaking waves.

desalination↗
NASA NTRS1972

Application of polyimide actuator rod seals

Development of polyimide two-stage hydraulic actuator rod seals for application in high-performance aircraft was accomplished. The significant portion of the effort was concentrated on optimization of the chevron and K-section second-stage seal geometries to satisfy the requirements for operation at 450 K (350 F) with dynamic pressure loads varying between 200 psig steady-state and 1500 psig impulse cycling. Particular significance was placed on reducing seal gland dimension by efficiently utilizing the fatigue allowables of polyimide materials. Other objectives included investigation of pressure balancing techniques for first-stage polyimide rod seals for 4000 psig 450 K(350 F) environment and fabrication of a modular retainer for the two-stage combination. Seals were fabricated in 0.0254 m (1.0in.) and 0.0635 m (2.5in.) sizes and tested for structural integrity, frictional resistance, and endurance life. Test results showed that carefully designed second stages using polyimides could be made to satisfy the dynamic return pressure requirements of applications in high-performance aircraft. High wear under full system pressure indicated that further research is necessary to obtain an acceptable first-stage design. The modular retainer was successfully tested and showed potential for new actuator applications.

Watermann, A. W.↗
DOE OSTI2024

The Design, Fabrication, and Test Program for NREL's Wave-Powered Desalination System: Preprint

Starting in 2018, the U.S. Department of Energy's Water Power Technologies Office (WPTO), initiated the development of a prize competition as a foundational investment of Powering the Blue Economy, The prize encouraged the development of small, modular, cost-competitive wave-powered desalination systems. The National Renewable Energy Laboratory (NREL) was tasked with managing the prize, known as the Waves to Water Prize (W2W), and providing technical input based on prior desalination research performed at the lab. NREL partnered with the Coastal Studies Institute (CSI) and Jennette's Pier in North Carolina for their expertise in deploying research articles at the Jennette's Pier research facility. The prize consisted of five stages that included high-level concept proposals, numerical modelling, site- specific design, subsystem prototyping, and a final ocean demonstration. Due to the logistical risks of installing numerous prototypes in the ocean at the same time, NREL was tasked with designing and building a test article to de- risk the final event. The test article design needed to represent the technologies expected in the final stage of the prize. This meant that the design was expected to follow the same rules as the competitors, providing CSI with an opportunity to practice installations and develop a final logistics plan prior to the final event. After concluding the W2W event in April 2022, the NREL test article was redeployed in August 2022 to better understand the challenges of anchoring wave energy converters (WECs) in shallow water conditions with breaking waves. For the Spanish version of this report, see NREL/CP-5700-88482 (https://www.nrel.gov/docs/fy24osti/88482.pdf).

deployment↗
DOE OSTI2021

Technology Development for Modular, Low-Cost, High-Temperature Recuperators for Supercritical CO 2 Power Cycles (Final Report)

The program’s focus was to evaluate, advance, and demonstrate recuperator design concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low-cost recuperators. Emphasis was placed on recompression closed Brayton cycles having a turbine inlet temperature exceeding 700°C and differential pressures on the order of 200 bar and were scalable to accommodate plant sizes from 10 to 1,000 MWe. The primary objectives of the first budget period, which included conceptual design, preliminary development, and prototype fabrication and testing, were accomplished. A new recuperator design concept, stacked-sheet heat exchanger (SSHX), was realized during the project. The design was taken from paper to hardware and successfully tested. The SSHX prototype recuperator met or exceeded program thermal, hydraulic and performance/cost metrics goals. The first budget period was extended to retire risk in scaling the recuperator from the kWt to MWt thermal capacity scale. The fabrication and design requirements for the budget period one extension were met. Delays associated with the Covid-19 pandemic prevented the fabrication and testing of the industrial scale prototype.

14 SOLAR ENERGY↗
DOE OSTI2026

Design of Multi-Engine Freight Locomotive

This final report documents the completed engineering design of a modular, multi-engine renewable natural gas (RNG) hybrid freight locomotive. The project delivered a full systems design, component selection, and production and test plans for a near-zero-emission, Tier 5–capable line-haul locomotive, but did not proceed to fabrication or field testing due to withdrawal of the designated engine supplier.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1979

Wideband digital spectrum analyzer

Modular spectrum analyzer consisting of RF receiver, fast fourier transform spectrum analyzer, and data processor samples stochastic signals in 220 channels. Construction reduces design and fabrication costs of assembled unit.

Morris, G. A., Jr.↗
DOE OSTI2020

Microreactor Agile Nonnuclear Experimental Testbed Test Plan

Microreactors are an attractive technology option for kick-starting nuclear innovation if they can be operated at high temperature, yielding high power conversion thermal efficiencies comparable or better than in commercial light water reactors. Microreactors are currently the smallest variation of Small Modular Reactors (SMRs). SMRs are “newer generation reactors designed to generate electric power up to 300 MWe and whose components and systems can be shop-fabricated and then transported as modules to the sites for installation as demand arises.” (IAEA, 2016). Vendors are developing microreactor designs to provide an affordable, potentially mobile source of electricity - see Fig. 1 for an example of a microreactor on a semi-truck. Various microreactor designs are possible including heat pipe- and gascooled options, which are the focus of the nonnuclear testing described in this document. In heat pipe microreactors, high-temperature heat pipes using liquid sodium or potassium working fluid transport fission heat from the core to a heat removal section which in turn transfers heat to the power conversion system working fluid. In a gas-cooled design, He or other gas will flow through a solid monolith of material and transfer heat as the temperature of the gas increases through a heat exchanger to a power conversion unit. The logistics of all these processes will be examined and tested through a series of articles at the nonnuclear test bed at Idaho National Laboratory (INL), the Microreactor Agile Nonnuclear Experiment Testbed (MAGNET) facility. Microreactors designed to produce power of 0.1-20 MWt offer the potential for more affordable nuclear energy for a range of applications. In a heat pipe microreactor, heat pipes, fuel rods, and/or moderator are intermixed in the reactor core assembly. Heat pipes extend from the core region into the heat removal section where the power conversion unit working fluid flows through holes or channels, transferring heat from the heat pipes to the working fluid. In a gas-cooled microreactor, gas flows through the solid monolith region and up into the heat exchanger region, transferring heat to the working fluid. For initial testing, the heat removal working fluid can be a low pressure gas for testing that addresses thermal stresses. In the final application, heat addition to the power conversion working fluid typically occurs at high pressure, supporting operation of an air-Brayton, supercritical CO 2 (SCO2), or He-recuperated Brayton cycle. Various stages of the steps above will be demonstrated through the tests described in this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1971

External fuel thermionic reactor system.

Thermionic reactors are prime candidates for nuclear electric propulsion. The national thermionic reactor effort is concentrated on the flashlight concept with the external-fuel concept as the backup. The external-fuel concept is very adaptable to a completely modular power subsystem which is attractive for highly reliable long-life applications. The 20- to 25-cm long, externally-fueled converters have been designed, fabricated, and successfully tested with many thermal cycles by electrical heating. However, difficulties have been encountered during encapsulation for nuclear heated tests and none have been started to date. These nuclear tests are required to demonstrate the concept feasibility.

Mondt, J. F.↗
DOE OSTI2022

Conceptual design of the modular detector and readout system for the CMB-S4 survey experiment

We present the conceptual design of the modular detector and readout system for the Cosmic Microwave Background – Stage four (CMB-S4) ground-based survey experiment. CMB-S4 will map the cosmic microwave background (CMB) and the millimeter-wave sky to unprecedented sensitivity, using 500,000 superconducting detectors observing from Chile and Antarctica to map over 60% of the sky. The fundamental building block of the detector and readout system is a detector module package operated at 100 mK, which is connected to a readout and amplification chain that carries signals out to room temperature. It uses arrays of feedhorn-coupled orthomode transducers (OMT) that collect optical power from the sky onto dc-voltage-biased transition-edge sensor (TES) bolometers. The resulting current signal in the TESs is then amplified by a two-stage cryogenic Superconducting Quantum Interference Device (SQUID) system with a time-division multiplexer to reduce wire count, and matching room-temperature electronics to condition and transmit signals to the data acquisition system. Sensitivity and systematics requirements are being developed for the detector and readout system over wide range of observing bands (20 to 300 GHz) and optical powers to accomplish CMB-S4’s science goals. While the design incorporates the successes of previous generations of CMB instruments, CMB-S4 requires an order of magnitude more detectors than any prior experiment. This requires fabrication of complex superconducting circuits on over 10 m2 of silicon, as well as significant amounts of precision wiring, assembly and cryogenic testing

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Embedded acoustic sensing and monitoring techniques for small modular reactors

The goal of this project was to study the applicability of specific innovative instrumentation techniques for assessing parameters needed for safe small modular reactor operation and safeguarding of nuclear material. Small modular reactor core designs are currently being developed to provide energy more effectively and efficiently than in the past because they can be built as modules at fabrication sites and then transported to a power-producing facility. However, these modules and/or the final core will often be sealed and not accessible again until disposal. Instead of instruments that access the core directly, during and after operation, to monitor flux/dose and structural integrity, as current power plants use, new sensors need to be designed that can be built into the reactor initially to determine operating history, structural integrity through operation of the system, and nuclear material accountancy after shutdown and before disposition of the core. Embedded sensors already exist that can provide neutron flux, gamma dose, and temperatures, but techniques to expand upon these for assessing structural health and material inventory in the system over time need to be developed. Structural health assessments include the detection and imaging of cracks in the components that could eventually cause radioactive fission products to be released.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1982

Concepts for an optimized Kirkpatrick-Baez mirror module for a high throughput LAMAR facility

Alternative concepts are proposed for the design and fabrication of Kirkpartick-Baez nested crossed plate reflectors applicable to a high throughput, moderate resolution X-ray facility composed of a Large Area Modular Array of Reflectors (LAMAR). Numerical, structural and optical analyses are used to quantify the performance characteristics of the concepts proposed. It is found that the theoretical performance of certain concepts approaches the 0.2-min resolution of a perfect parabola of translation. The instrument under consideration has about 1000 sq cm of effective area, or five times greater area than that of the Einstein Observatory.

Cohen, L. M.↗
NASA NTRSDate not supplied

Design and Fabrication of the Langley Aerodrome No. 8 - Distributed Electric Propulsion VTOL Testbed

The Langley Aerodrome No. 8 (LA-8) is a distributed electric propulsion, vertical takeoff and landing (VTOL) aircraft that is being used for wind tunnel testing and free flight testing at the NASA Langley Research Center. The intent of the LA-8 project is to provide a low-cost, modular test bed for technologies in the area of Advanced Air Mobility which includes electric urban and short regional flight. The methods used on the LA-8 provide a rapid means to verify aerodynamic, acoustic, and flight dynamics analysis of new electric VTOL and short takeoff and landing (STOL) designs. In addition, the flight vehicle will be used to help develop test processes for FAA flight vehicle airworthiness certification and for the development of robust flight control algorithms that are tolerant of failures. A new approach is being used on test vehicle design that makes extensive use of 3-D printing. Although materials used in 3-D printing have less strength than traditional materials used for NASA’s wind tunnel and flight models, strategic placement of load-carrying structures allows the aircraft to meet structural criteria while also enabling easy changes to be made in the vehicle design, such as the outer mold line. Modularity of the vehicle’s main components allows rapid changes to the vehicle configuration for comparative evaluation of alternate designs. Finally, a description is given of detailed inertia measurements of the flight vehicle using compound pendulum swing methods.

Urban air mobility↗
DOE OSTI2020

DOE Hanford Tank Side Cesium Removal System (TSCR) Update: Fabrication and Factory Acceptance Testing - 20300

The Tank Side Cesium Removal (TSCR) System is a modular, quickly-deployable, and passively safe system for efficiently removing solids and cesium from alkaline liquid waste raffinate created by fuel processing on the Hanford site. This paper provides an overview of the project with particular emphasis on completion of fabrication and factory acceptance testing (FAT). All TSCR System components are inside three enclosures known as the Process Enclosure, Ancillary Enclosure, and Control Enclosure. The Process Enclosure is seismic design category II (SDC-II) and built to withstand the rigors of transportation and lifting, high winds, volcanic ash fall, and heavy precipitation (snow) over a temperature range of -25 to 115 deg. F. The Process Enclosure and Control Enclosure were fabricated in AVANTech's Columbia, SC facility, while the Ancillary Enclosure was fabricated in AVANTech's Richland, WA facility. The design and preliminary documented safety analysis were completed in December 2019, with all work being performed in accordance with ASME NQA-1 quality assurance requirements. The Process Enclosure, Ion Exchange Columns (IXCs), and several other TSCR components have a nuclear safety function and are designated as safety significant structures, systems, and components (SS-SSCs). The NQA-1 Commercial Grade Dedication (CGD) process was used to identify critical characteristics in order to accept materials and items used for fabrication of several safety significant TSCR components. This paper also addresses unique aspects and challenges of implementing CGD in DOE facilities and systems. After fabrication and preliminary testing, the Process and Control Enclosures were shipped to AVANTech's Richland facility where the complete TSCR System was setup and connected in a represented layout and configuration that will be used on the Hanford site. Test tanks and pumps were put in place and connected to the TSCR Process Enclosure in a manner that mimicked interfacing Double Shell Tanks in the 241-AP Tank Farm. The TSCR System was then tested/operated under conditions equivalent to those planned for onsite operation. Testing was separated into five separate phases as defined below: - Phase 1: Confirmation of TSCR System readiness for the FAT; - Phase 2: Verification of TSCR System operation under standard conditions; - Phase 3: Demonstration of TSCR System operation under non-standard conditions; - Phase 4: Demonstration of ion exchange media removal from an IXC; and - Phase 5: Completion of TSCR System lift plans and site mobilization. The Hanford Tank Operations Contractor, Washington River Protection Solutions (WRPS), participated in all phases of testing. Testing at AVANTech's Richland Facility allowed WRPS personnel to familiarize themselves with TSCR operations in a radiologically clean facility prior to onsite mobilization. Engineering and operations personnel gained valuable experience that allowed them to better refine onsite operational protocols and procedures - including handling and movement of IXCs with a forklift. This paper describes the technologies used by the TSCR System as well as how these technologies are deployed and operated to advance the Hanford mission of safely, efficiently, and effectively treating tank waste. It also provides detailed information on fabrication and FAT, including operational data from simulated tank waste runs. A project schedule for WRPS' planned construction acceptance testing, operational acceptance testing, and actual tank waste treatment is provided. This presentation should be of great interest to parties responsible for the design, testing, and mobilization of modular NQA-1 technologies for the treatment of raffinate and similar liquid wastes containing high concentrations of radioactive cesium. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1995

A three-dimensional orthogonal laser velocimeter for the NASA Ames 7- by 10-foot wind tunnel

A three-component dual-beam laser-velocimeter system has been designed, fabricated, and implemented in the 7-by 10-Foot Wind Tunnel at NASA Ames Research Center. The instrument utilizes optical access from both sides and the top of the test section, and is configured for uncoupled orthogonal measurements of the three Cartesian coordinates of velocity. Bragg cell optics are used to provide fringe velocity bias. Modular system design provides great flexibility in the location of sending and receiving optics to adapt to specific experimental requirements. Near-focus Schmidt-Cassegrain optic modules may be positioned for collection of forward or backward scattered light over a large solid angle, and may be clustered to further increase collection solid angle. Multimode fiber optics transmit collected light to the photomultiplier tubes for processing. Counters are used to process the photomultiplier signals and transfer the processed data digitally via buffered interface controller to the host MS-DOS computer. Considerable data reduction and graphical display programming permit on-line control of data acquisition and evaluation of the incoming data. This paper describes this system in detail and presents sample data illustrating the system's capability.

Dunagan, Stephen E.↗