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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 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Thermal Modeling of a Dual-Stage Sodium Thermal-Electrochemical Converter (Na-TEC)

The sodium thermal electrochemical converter (Na-TEC) is a heat engine that generates electricity through the isothermal expansion of sodium ions through a beta”-alumina solid-electrolyte. The Na-TEC is a closed system that can theoretically achieve conversion efficiencies above 45% when operating between thermal reservoirs at 1150 K and 550 K. However, thermal designs have confined previous single-stage devices to thermal efficiencies below 20%. To mitigate some of these limitations, we consider dividing the isothermal expansion into two stages; one at the evaporator temperature (1150 K) and another at an intermediate temperature (550 K – 950 K). This dual-stage Na-TEC takes advantage of regeneration and reheating, and could be amenable to better thermal management through a reduction of parasitic losses. These losses are comprised of (i) the heat input that does not participate in power production but simply bypasses the thermo-electrochemical process and is transferred to the condenser, and (ii) heat that is lost from the device directly to the surroundings due to poor insulation. Heat loss to the surroundings occurs from a lower average hot-side temperature given that a fraction of the power conversion occurs at an intermediate stage. Also, the condenser now directly interacts with the lower temperature of the intermediate stage, thereby reducing radiation loss. A simplified geometry is developed for this device to help guide its design from a heat transfer perspective. All thermal contact and boundary conditions are discussed, including the evaporation and condensation of sodium vapor, thermal leakage through the housing, and the thermal contact between the beta”-alumina and the housing. A ray tracing method assuming gray, diffuse surfaces is used to account for the internal radiation heat transfer within the device. Liquid sodium flows in a capillary wick between the condenser and the evaporator with Pe << 1, so only conduction heat transfer is considered within this liquid return path. For simplicity, natural convection between the sodium vapor and the device housing is neglected. A numerical linear resistance model (<5% error when compared to a finite element model) is used to determine the expected conversion temperatures of each stage for a range of candidate materials. Furthermore, a numerical model (<2% error) is developed to find the factor of increase in the thermal resistance for several designs of corrugated features for the device housing. By using an iterative scheme, efficiency vs. power curves are created for a number of material and size combinations. Finally, the fundamental tradeoff between the power and efficiency is explored in conjunction with the total system size.

14 SOLAR ENERGY↗
DOE OSTI2022

Modeling of the AGR 3/4 PIE Experiments

TRISO Fuel Accident Scenarios Transport of Fission Products (FP) through modern nuclear-grade graphites is not well established The AGR 3/4 experimental results need to be modeled to extract FP transport characteristics A finite element model using graphite diffusivities from IAEA TECDOC-978 is compared against measured results

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Optimization of overhang printing in ceramic binder jetting additive manufacturing

Cylindrical-shaped horizontally-hanging overhangs with different heights on a solid cubic body were printed via binder jetting additive manufacturing with sililcon carbide powder feedstock. Cracking on the overhang neck and sagging on the overhang body were observed both pre- and post-curing, especially on printed design with a smaller particle size of 10 μm. Here, it was found that the width of cracking and depth of sagging were dependent on the height relative to the solid body in the powder bed, and elevated position of overhang with large volume of underneath loose powder led to increased extend of cracking and sagging. Overhang diameter and weight were varied, which were found with no apparent effects on its deformation extend. To mitigate cracking and sagging, contactless support was designed and tested, which could significantly improve the overhang stability and avoid any overhang deformations. Support gap and support distance were studied for their effects on support capability. The printing processes with and without contactless support were simulated by a finite element modeling approach to understand the stress distribution and evolution of the overhang structures, which revealed stress concentrations on the upper neck point of the designed overhang.

Binder jetting↗
DOE OSTI2024

Additive Manufacturing with Cellulose-Based Composites: Materials, Modeling, and Applications

Recent advances in large-scale additive manufacturing (AM) with polymer-based composites have enabled efficient production of high-performance materials. Cellulose nanomaterials (CNMs) have emerged as bio-based feedstocks due to their exceptional strength and sustainability. However, challenges such as hornification and poor dispersion in polymer matrices still limit large-scale CNM–polymer composite manufacturing, requiring novel strategies. Here, this review outlines an approach starting with atomic-level simulations to link molecular composition to key parameters like bulk density, viscosity, and modulus. These simulations provide data for finite element analysis (FEA), which informs large-scale experiments and reduces the need for extensive trials. The strategy explores how atomic interactions impact the morphology, adhesion, and mechanical properties of CNM-based composites in AM processes. The review also discusses current developments in AM, along with predictions of mechanical and thermal properties for structural applications, packaging, flexible electronics, and hydrogel scaffolds. By integrating experimental findings with molecular dynamics (MD) simulations and finite element modeling (FEM), valuable insights for material design, process optimization, and performance enhancement in CNM-based AM are provided to address ongoing challenges.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Modeling of Fillets in Thin-Walled Structures for Dynamic Analysis

Relatively new developments in manufacturing methods have made it possible to produce machined parts with a wall thickness of less than 0.010". While the parts are being machined. Fillets of relatively large radius to thickness ratios are created by the milling tool. This paper discusses an accurate new technique for finite-element modeling of fillets for dynamic and stiffness analysis using efficient plate elements rather than more computationally intensive, high density solid meshes, A simple filleted cantilever beam of 0.040" thickness, 1.6" length, 1" depth, and 0.250" radius in the corner was modeled using both solid elements and several different plate element geometries. The finite element results were then compared with static and modal testing of a machined sample. The highest-scoring plate element technique uses a bridge of elements that is constructed through the tangent point of the Fillet radius such that the thickness of the element matches tile volume of the fillet. This model produces errors of less than 4.6 percent for static loading and less than 7.4 percent for modal analysis. This simple plate element technique will prove critical for efficient, timely, and accurate dynamic analysis of complex thin-walled structures.

Seugling, Richard M.↗
DOE OSTI2016

Three-dimensional local residual stress and orientation gradients near graphite nodules in ductile cast iron [3D local residual stress and orientation gradients near graphite nodules in ductile cast iron]

A synchrotron technique, differential aperture X-ray microscopy (DAXM), has been applied to characterize the microstructure and analyze the local mesoscale residual elastic strain fields around graphite nodules embedded in ferrite matrix grains in ductile cast iron. Compressive residual elastic strains are measured with a maximum strain of ~6.5–8 × 10 –4 near the graphite nodules extending into the matrix about 20 μm, where the elastic strain is near zero. The experimental data are compared with a strain gradient calculated by a finite element model, and good accord has been found but with a significant overprediction of the maximum strain. This is discussed in terms of stress relaxation during cooling or during storage by plastic deformation of the nodule, the matrix or both. Furthermore, relaxation by plastic deformation of the ferrite is demonstrated by the formation of low energy dislocation cell structure also quantified by the DAXM technique.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Spark plasma sintering of structure-tailored ultrahigh-temperature components: First step to complex net shaping

The net-shaping capability in spark plasma sintering (SPS) of ultrahigh-temperature ceramics has been explored in this study. The annular or ring-like shape is considered here as the first step to a more complex geometry compared to a solid cylinder or disk. ZrC powders have been SPS processed in specially designed graphite tooling to achieve the annular shape geometry. Experimental runs have been carried out to determine the optimal processing parameters for producing highly dense ZrC specimens in this geometry. Finite-element modeling framework has been constructed to determine the internal stress evolution, as well as densification, during the SPS of the annular-shaped ZrC. The formulated processing schemes for ZrC have been adapted to process SiC/ZrB2 composite powder with the purpose of making tooling components for SPS applications. The applicability of the obtained composite SPS tooling has been evaluated at high temperature and high pressure associated with SPS regimes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure Clones

Background: A material’s microstructure drives its material performance. Contemporary crystal plasticity experiments compare full-field strain measurements of polycrystal specimens to models. Because each specimen is unique, it is impossible to know which features of the observed deformation are deterministic vs statistical; thus, differences between model and experiment may or may not be significant. Objective: This paper introduces the invention of microstructure clones. Microstructure clones are 2D oligocrystal specimens that have nearly identical microstructures to remedy the aforementioned experimental limitations. Having specimens with nearly identical microstructures will allow for multiple destructive tests of a microstructure (either as repeats or intentionally different experiments), an ability to “see the future” by providing insight into how a specimen will deform, variability quantification, and experimental investigations of response to small microstructural changes. Methods: This work introduces microstructure clones. Repeatability of these clones is demonstrated in tensile bars of pure nickel. Local strain measurements from digital image correlation are compared between clone specimens and compared to results from a crystal plasticity finite element model. Results: Two sets of microstructure clones were tested in this study and displayed very consistent deformation responses within each clone set. Small observed differences in deformation invite investigation into microstructure stochasticity and the effect of small microstructural and loading differences. Conclusions: Microstructure clones represent a significant shift in understanding structure–property relationships. This work reshapes experimental crystal plasticity to allow for experiments that control for specific variables, quantification of microstructural stochasticity (and other sources of stochasticity), and opportunities for replicating experiments.

Crystal Plasticity↗
NASA NTRSDate not supplied

Composite Progressive Delamination Analysis of Thin Ply Buckling

The NASA Advanced Composites Project is a multi-year consortium of government, industry and academia to develop and validate technology that will reduce development and certification of advanced composite materials for aircraft structures. One of its tasks is to simulate and predict composite damage progression accurately through high fidelity finite element models. It included a subtask to verify an approach based on the Virtual Crack Closure Technology (VCCT) as well as Floating Node Method (FNM). This paper discusses predicted damage onset and growth in a thin-ply buckling problem. Sensitivity of the simulations to various initial crack length is studied. The compressive load-displacement curves are plotted and the crack growth critical load is predicted. Overall, the crack progression follows simulation benchmarks well. However, the critical-load overshoot phenomenon is observed in both VCCT and FNM, suggesting further investigation may be worth pursuing.

damage progression↗
DOE OSTI2018

Thermal modeling and efficiency of a dual-stage sodium heat engine

In this paper, a thermal design of an axisymmetric dual-stage sodium thermal electrochemical converter (Na-TEC) is presented, where a reduced-order finite-element model is used in conjunction with a Na-TEC thermodynamic model to determine the total parasitic heat loss of this dual-stage design. A number of simplifications are applied in the reduced-order model to decrease the computational time while maintaining acceptable accuracy. These include the use of effective thermal conductivities to account for complex corrugated geometries and apparent surface emissivities to accommodate the effect of radiation shields. Furthermore, a simplified analytical model is developed to account for conduction bypass through the Na-TEC liquid-return path. An iterative procedure between the finite-element and thermodynamic models is described in detail, and the thermal performance of the design proposed herein is analyzed. According to this analysis, a maximum efficiency of 29% and a maximum power output of 125 W can be achieved.

14 SOLAR ENERGY↗
DOE OSTI2016

Formulation and numerical analysis of a fully-coupled dynamically deforming electromagnetic wire

Here, an electromagnetic beam model is developed for the simulation of actuated electronic textiles. The beam is solved using a nonlinear director-based kinematic description with additional temperature and electric potential fields along its length. The three fields are fully coupled by mutual dependences on the deformation, Lorenz force, back electromotive force, temperature dependent constitutive responses, and the Seebeck effect. Instead of solving Maxwell's equations in full detail, a quasistatic approximation is used to solve the electric potential in the presence of a moving material medium. The current-carrying beam approximation is used to further simplify the solution space for the potential. While this formulation alleviates the spatial and temporal discretization restrictions, the coupled problem is an index-1 semi-explicit Differential Algebraic Equation requiring special treatment. The time dependent problem is solved using different Runge-Kutta methods. Diagonally implicit Runge-Kutta methods and explicit Runge-Kutta methods using implicit solution of the electric potential problem are explored. The finite element model is implemented using the open source package FEniCS, which is able to automatically generate the linearizations of the multiphysics equations required for the implicit solutions. A model problem is constructed with which to test and analyze the physical formulation and numerical solution techniques. The time stepping methods are verified using the convergence orders of the higher-order Runge-Kutta methods. Runtime comparisons show that the explicit methods are generally more computationally efficient than the implicit schemes used for this problem. For the implicit schemes, a staggered solution is significantly faster than a monolithic solution at most time step sizes. However, at very large time steps, such as those that would be used for dynamic relaxation, the monolithic solution can be more efficient than the staggered solution.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Combined ambient vibration and surface displacement measurements for improved progressive failure monitoring at a toppling rock slab in Utah, USA

Seismic resonance and surface displacement measurements can be implemented in tandem to improve landslide characterization and progressive failure monitoring. Crack aperture data are frequently used in rock slope stability monitoring and often exhibit recognizable trends prior to failure, such as accelerated crack opening. Alternatively, ambient resonance data offer multiple parameters including modal frequencies, damping, and polarization that can be monitored alongside crack aperture and may respond differently to environmental forcings and complex failure evolution. We analyzed data from continuous ambient vibration monitoring and concomitant crack aperture measurements at the Courthouse Mesa instability, a large toppling sandstone slab in Utah, USA. Three years of data revealed crack aperture increases of 2–4 mm/year with no clearly detectable irreversible changes in modal parameters, including frequency. Annually, frequency and displacement varied by 29% and 19% of the mean, respectively, with average and maximum daily frequency fluctuations of 6.5% and 16%, respectively. These reversible cyclic changes were primarily temperature-driven, but annually, frequency was in-phase with temperature whereas crack aperture lagged temperature changes by ~37 days. Polarization and damping also varied seasonally but were less strongly correlated with temperature. Conceptual 3D finite element modeling demonstrated consistent frequency decreases associated with crack propagation but variable changes in crack aperture measured at a single point; i.e., crack propagation did not always result in increased crack opening but always generated a resonance frequency decrease. Taken together, our data suggest a possible thermal wedging-ratcheting mechanism at the Courthouse Mesa instability, where annual thermoelastic crack closure is impeded by debris infill but the absence of downward crack propagation during the monitoring period is evidenced by no permanent resonance frequency changes. Our study demonstrates that combined seismic resonance and crack aperture data provide an improved description of rock slope instability behavior, supporting refined characterization and monitoring of changes accompanying progressive failure.

58 GEOSCIENCES↗
DOE OSTI2021

Editors’ Choice—Natural Convection Boundary Layer Thickness at Elevated Chloride Concentrations and Temperatures and the Effects on a Galvanic Couple

The natural convection boundary layer ( δ n c ) and its influence on cathodic current in a galvanic couple under varying electrolytes as a function of concentration (1 − 5.3 M NaCl) and temperature (25 °C−45 °C) were understood. Polarization scans were obtained under quiescent conditions and at defined boundary layer thicknesses using a rotating disk electrode on platinum and stainless steel 304L (SS304L); these were combined to determine δ n c . With increasing chloride concentration and temperature, δ n c decreased. Increased mass transport (Sherwood number) results in a decrease in δ n c , providing a means to predict this important boundary. Using Finite Element Modeling, the cathodic current was calculated for an aluminum alloy/SS304L galvanic couple as a function of water layer ( WL ) thickness and cathode length. Electrolyte domains were delineated, describing (i) dominance of ohmic resistance over mass transport under thin WL , (ii) the transition from thin film to bulk conditions at δ n c , and (iii) dominance of mass transport under thick WL . With increasing chloride concentration, cathodic current decreased due to decreases in mass transport. With increasing temperature, increased cathodic current was related to increases in mass transport and solution conductivity. This study has implications for sample sizing and corrosion prediction under changing environments.

25 ENERGY STORAGE↗
DOE OSTI2015

Novel Monitoring Techniques for Characterizing Frictional Interfaces in the Laboratory

A pressure-sensitive film was used to characterize the asperity contacts along a polymethyl methacrylate (PMMA) interface in the laboratory. The film has structural health monitoring (SHM) applications for flanges and other precision fittings and train rail condition monitoring. To calibrate the film, simple spherical indentation tests were performed and validated against a finite element model (FEM) to compare normal stress profiles. Experimental measurements of the normal stress profiles were within -7.7% to 6.6% of the numerical calculations between 12 and 50 MPa asperity normal stress. The film also possessed the capability of quantifying surface roughness, an important parameter when examining wear and attrition in SHM applications. A high definition video camera supplied data for photometric analysis (i.e., the measure of visible light) of asperities along the PMMA-PMMA interface in a direct shear configuration, taking advantage of the transparent nature of the sample material. Normal stress over individual asperities, calculated with the pressure-sensitive film, was compared to the light intensity transmitted through the interface. We found that the luminous intensity transmitted through individual asperities linearly increased 0.05643 ± 0.0012 candelas for an increase of 1 MPa in normal stress between normal stresses ranging from 23 to 33 MPa.

47 OTHER INSTRUMENTATION↗
NASA NTRS1983

Propagation of flexural and membrane waves with fluid loaded NASTRAN plate and shell elements

Modeling of flexural and membrane type waves existing in various submerged (or in vacuo) plate and/or shell finite element models that are excited with steady state type harmonic loadings proportioned to e(i omega t) is discussed. Only thin walled plates and shells are treated wherein rotary inertia and shear correction factors are not included. More specifically, the issue of determining the shell or plate mesh size needed to represent the spatial distribution of the plate or shell response is of prime importance towards successfully representing the solution to the problem at hand. To this end, a procedure is presented for establishing guide lines for determining the mesh size based on a simple test model that can be used for a variety of plate and shell configurations such as, cylindrical shells with water loading, cylindrical shells in vacuo, plates with water loading, and plates in vacuo. The procedure for doing these four cases is given, with specific numerical examples present only for the cylindrical shell case.

Kalinowski, A. J.↗
DOE OSTI2023

Full-Field Strain Measurement Integrated with Two Dimension Regression Analysis to Evaluate the Bi-Modulus Elastic Properties of Isotropic and Transversely Isotropic Materials

Background: Measuring the physical properties of shale is critical for optimizing engineering activities such as geothermal energy generation and hydraulic fracturing. Shale is a transversely isotropic material. Furthermore, this material can also include micro and macro cracks at different locations and orientations that cause it to behave differently under tensile or compressive loading. Objective: In this work, a combined experimental–numerical approach is proposed to evaluate the bi-modulus elastic properties of isotropic and transversely isotropic materials. Methods: Full-field strain measurements for a circular disk under diametral compression are integrated with a regression analysis technique to evaluate the elastic properties of bi-modulus materials subjected to tensile and compressive loads using two loading configurations on the same specimen. Digital Image Correlation (DIC) is used to measure the full-field strains. Subsequently, in the case of an isotropic material, a linear least-squares approach is utilized to process the experimentally determined strains in conjunction with analytical expressions of the stress fields (in terms of far-field loading) to determine the elastic modulus E, the shear modulus G, and the Poisson’s ratio $v$. In the case of a transversely isotopic material, such as shale, a finite element model is implemented to determine the stress fields (again in terms of far-field loading), which is followed by repeating the previous regression analysis in an iterative process to estimate the elastic parameters. Results: The results show that the proposed technique successfully provides a complete set of elastic properties as a function of both the loading condition and the principal material directions. The technique is validated by measurements on a known isotropic material and then applied to determine the properties of shale. Conclusion: In this work, the proposed approach is successfully used to calculate the bi-modulus elastic response of poly(methyl meth- acrylate) (PMMA) and shale. As expected, PMMA exhibits an isotropic response with no bi-modulus effect, however, shale exhibits both transverse isotropy and a bi-modulus effect. Therefore, this approach holds promise for investigating the elastic properties of materials like rocks and fiber-reinforced composite laminates as functions of the principal material directions and the loading conditions.

42 ENGINEERING↗
DOE OSTI2022

Trunk muscle forces and spinal loads while walking in persons with lower limb amputation: Influences of chronic low back pain

Persons with lower limb amputation (LLA) are at high risk for developing chronic low back pain (LBP), often with biomechanical factors considered as likely contributors. Here, trunk and pelvis kinematics, muscle forces, and resultant spinal loads were characterized in persons with LLA, with and without chronic LBP. Thirty-five persons with unilateral LLA – 19 with chronic LBP (“LLA-cLBP”), 16 without LBP (“LLA-nLBP”) – and 15 (uninjured) persons without LBP (“CTR-nLBP”) walked overground (1.3 m/s) while thorax and pelvis kinematics were tracked (and ranges of motion [ROM] computed), and used as inputs for a non-linear finite element model of the spine to estimate global and local muscle forces, and resultant spinal loads. In the frontal and transverse planes, thorax ROM were up to 66.6% smaller in LLA-nLBP versus LLA-cLBP (P < 0.001) and CTR-nLBP (P < 0.001). In the sagittal plane, pelvis ROM was 50.4% smaller in LLA-nLBP versus LLA-cLBP (P = 0.014). LLA-cLBP exhibited 45.5% and 34.2% greater peak local and global muscle forces, respectively, versus CTR-nLBP (P < 0.011). Up to 48.1% greater spinal loads were observed in LLA-cLBP versus CTR-nLBP (P < 0.013); peak compression and local muscle forces were respectively 20.2% and 41.0% larger in LLA-nLBP versus CTR-nLBP (P < 0.005). Despite differences in trunk and pelvis kinematics between LLA-cLBP and LLA-nLBP, trunk muscle forces and spinal loads were similar (P > 0.101) between these groups. Similar loading parameters regardless of LBP presence, while highly dependent on trunk muscle activation strategies, may mitigate further accumulation of mechanical fatigue. Finally, it remains important to understand the temporality of loading with respect to LBP onset following LLA.

60 APPLIED LIFE SCIENCES↗