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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Composite manufacturing↗
DOE OSTI2021

Power System Modeling for the Study of High Penetration of Distributed Photovoltaic Energy

Many conventional power systems are evolving due to the growth of renewable energy and distributed energy resources (DERs). Modeling the interplay of transmission and distribution systems is critical to analyze how DERs impact a system’s conventional operation and which electric infrastructure improvements are needed to achieve a balance between centralized generation and DERs. This article describes the process, tools, and resources used to model electric power systems with a centralized infrastructure in an isolated context and limited access to actual utility data. Photovoltaic systems installed on residential rooftops were the main design option. This work broadened the typical power system modeling to include planning and social considerations. This integrative engineering-social method allows for interdisciplinary teams to work in the development of a model as part of broader design goals for a renewable-dominant energy system. The Puerto Rico electric power system was used as a case study to demonstrate the process. The integrative engineering-social perspective in developing the model and the actions to manage data limitations are aspects that could be followed in other locations with aggressive renewable energy goals and where utility data are not readily available.

Cuello-Polo, Gustavo↗
NASA NTRS1982

Large area space solar cell assemblies

Results of the development of a 34.3 sq cm space solar cell and integral glass cover are presented. Average AM(0) cell efficiency is 14 percent. The cell design includes a high performance back surface reflector yielding a thermal alpha of approximately 0.66. A novel process is described which integrates cell fabrication and encapsulation thereby achieving a reduction of encapsulation cost. Test results indicate the potential of this new technology.

Nowlan, M. J.↗
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↗
DOE OSTI2018

Hybridization of IMC and PID control structures based on filtered GPC using genetic algorithm

Classical and advanced hybridization methods are employed in the control literature to calibrate the tuning parameters of internal model control (IMC) and proportional-integral-derivative (PID) controllers. This paper presents an alternative tuning design for the generalized predictive controller (GPC) that is based on both the positional process model and cost function. The proposed method involves the selection of an integral polynomial weighting filter for reference and output signals to deal with reference tracking, disturbance rejection, model-plant mismatch (MPM), minimum control energy and closed-loop robustness. The filter positional GPC (FP-GPC) obtained is transformed into a two-degree-of-freedom polynomial filtered RST structure and then into filtered internal model control (F-IMC) and PID controllers. Also, a multi-objective optimization based on genetic algorithm is applied to tune the filter parameters. Numerical and experimental essays show the effectiveness of the proposed control methodology.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

SU-G-IeP3-09: Investigating the Interplay of Antiscatter Grids with Modern Detectors and Image Processing in Digital Radiography

Purpose: To use phantom and simulation experiments to relate technique factors, patient size and antiscatter grid use to image quality in portable digital radiography (DR), in light of advancements in detector design and image processing. Methods: Image contrast-to-noise ratio (CNR) on a portable DR system (MobileDaRt Evolution, Shimadzu) was measured by imaging four aluminum inserts of varying thickness, superimposed on a Lucite slab phantom using a pediatric abdominal protocol. Three thicknesses of Lucite were used: 6.1cm, 12cm, and 18.2cm, with both 55 and 65 kVp beams. The mAs was set so that detector entrance exposure (DEE) was matched between kVp values. Each technique and phantom was used with and without an antiscatter grid (focused linear grid embedded in aluminum with an 8:1 ratio). The CNR-improvement-factor was then used to determine the thickness- and technique-dependent appropriateness of grid use. Finally, the same experiment was performed via Monte Carlo simulation, integrating incident energy fluence at each detector pixel, so that effects of detector design and image processing could be isolated from physical factors upstream of the detector. Results: The physical phantom experiment demonstrated a clear improvement for the lower tube voltage (55kVp), along with substantial CNR benefits with grid use for 12–18cm phantoms. Neither trend was evident with Monte Carlo, suggesting that suboptimal quantum-detection-efficiency and automated grid-removal could explain trends in kVp and grid use, respectively. Conclusion: Physical experiments demonstrate marked improvement in CNR when using a grid for phantoms of 12 and 18cm Lucite thickness (above ∼10cm soft-tissue equivalent). This benefit is likely due to image processing, as this result was not seen with Monte Carlo. The impact of image processing on image resolution should also be investigated, and the CNR benefit of low kVp and grid use should be weighed against the increased exposure time necessary to achieve adequate DEE.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Dilute Alloys Based on Au, Ag, or Cu for Efficient Catalysis: From Synthesis to Active Sites

The development of new catalyst materials for energy-efficient chemical synthesis is critical as over 80% of industrial processes rely on catalysts, with many of the most energy-intensive processes specifically using heterogeneous catalysis. Catalytic performance is a complex interplay of phenomena involving temperature, pressure, gas composition, surface composition and structure over multiple length and time scales. In response to this complexity, the integrated approach to heterogeneous dilute-alloy catalysis reviewed here brings together materials synthesis, mechanistic surface chemistry, reaction kinetics, in-situ and operando characterization, and theoretical calculations in a coordinated effort to develop design principles to predict and improve catalytic selectivity. Dilute alloy catalysts—in which isolated atoms or small ensembles of the minority metal on the host metal lead to enhanced reactivity while retaining selectivity—are particularly promising as selective catalysts. Several dilute alloy materials using Au, Ag and Cu as the majority host element, including more recently introduced support-free nanoporous metals and oxide-supported nanoparticle "raspberry colloid templated (RCT)" materials, are reviewed for selective oxidation and hydrogenation reactions. Progress in understanding how such dilute alloy catalysts can be used to enhance selectivity of key synthetic reactions is reviewed, including quantitative scaling from model studies to catalytic conditions. The dynamic evolution of catalyst structure and composition studied in surface science and catalytic conditions and their relationship to catalytic function are also discussed, followed by advanced characterization and theoretical modeling that have been developed to determine the distribution of minority metal atoms at or near the surface. Furthermore, the integrated approach demonstrates the success of bridging the divide between fundamental knowledge and design of catalytic processes in complex catalytic systems, which can accelerate the development of new and efficient catalytic processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗
NASA NTRS2011

Full-Scaled Advanced Systems Testbed: Ensuring Success of Adaptive Control Research Through Project Lifecycle Risk Mitigation

The National Aeronautics and Space Administration's Dryden Flight Research Center completed flight testing of adaptive controls research on the Full-Scale Advance Systems Testbed (FAST) in January of 2011. The research addressed technical challenges involved with reducing risk in an increasingly complex and dynamic national airspace. Specific challenges lie with the development of validated, multidisciplinary, integrated aircraft control design tools and techniques to enable safe flight in the presence of adverse conditions such as structural damage, control surface failures, or aerodynamic upsets. The testbed is an F-18 aircraft serving as a full-scale vehicle to test and validate adaptive flight control research and lends a significant confidence to the development, maturation, and acceptance process of incorporating adaptive control laws into follow-on research and the operational environment. The experimental systems integrated into FAST were designed to allow for flexible yet safe flight test evaluation and validation of modern adaptive control technologies and revolve around two major hardware upgrades: the modification of Production Support Flight Control Computers (PSFCC) and integration of two, fourth-generation Airborne Research Test Systems (ARTS). Post-hardware integration verification and validation provided the foundation for safe flight test of Nonlinear Dynamic Inversion and Model Reference Aircraft Control adaptive control law experiments. To ensure success of flight in terms of cost, schedule, and test results, emphasis on risk management was incorporated into early stages of design and flight test planning and continued through the execution of each flight test mission. Specific consideration was made to incorporate safety features within the hardware and software to alleviate user demands as well as into test processes and training to reduce human factor impacts to safe and successful flight test. This paper describes the research configuration, experiment functionality, overall risk mitigation, flight test approach and results, and lessons learned of adaptive controls research of the Full-Scale Advanced Systems Testbed.

Pavlock, Kate M.↗
NASA NTRS1990

Shape optimization and CAD

Structural optimization has attracted the attention since the days of Galileo. Olhoff and Taylor have produced an excellent overview of the classical research within this field. However, the interest in structural optimization has increased greatly during the last decade due to the advent of reliable general numerical analysis methods and the computer power necessary to use them efficiently. This has created the possibility of developing general numerical systems for shape optimization. Several authors, eg., Esping; Braibant & Fleury; Bennet & Botkin; Botkin, Yang, and Bennet; and Stanton have published practical and successful applications of general optimization systems. Ding and Homlein have produced extensive overviews of available systems. Furthermore, a number of commercial optimization systems based on well-established finite element codes have been introduced. Systems like ANSYS, IDEAS, OASIS, and NISAOPT are widely known examples. In parallel to this development, the technology of computer aided design (CAD) has gained a large influence on the design process of mechanical engineering. The CAD technology has already lived through a rapid development driven by the drastically growing capabilities of digital computers. However, the systems of today are still considered as being only the first generation of a long row of computer integrated manufacturing (CIM) systems. These systems to come will offer an integrated environment for design, analysis, and fabrication of products of almost any character. Thus, the CAD system could be regarded as simply a database for geometrical information equipped with a number of tools with the purpose of helping the user in the design process. Among these tools are facilities for structural analysis and optimization as well as present standard CAD features like drawing, modeling, and visualization tools. The state of the art of structural optimization is that a large amount of mathematical and mechanical techniques are available for the solution of single problems. By implementing collections of the available techniques into general software systems, operational environments for structural optimization have been created. The forthcoming years must bring solutions to the problem of integrating such systems into more general design environments. The result of this work should be CAD systems for rational design in which structural optimization is one important design tool among many others.

Rasmussen, John↗
DOE OSTI2026

INR-TEM: Robust cavity detection in multifocus TEM images via implicit neural representations

When characterizing materials using transmission electron microscopy (TEM) images, detecting and quantifying small features in microstructures, such as cavities, pose significant challenges. Off-the-shelf object detection models, including YOLOv8, show considerable performance degradation, particularly when images vary in resolution and the objects of interest possess a low percentage of the total image region of interest. In this study, we introduce a novel detection pipeline that incorporates an implicit neural representation (INR)-based detection method, INR-TEM, and two-modality imaging (e.g., under-focused and over-focused images typically acquired during materials characterization) to improve object detection performance. The INR-TEM method incorporates a pixel-wise prediction principle inspired by pixel-wise centerness weighting. INR-TEM demonstrates superior robustness to resolution variability, maintaining high detection accuracy even at low image resolutions compared to YOLOv8. To leverage INR-TEM effectively in real-world two-modality characterization applications, we further integrate a two-stage motion correction pipeline designed explicitly for aligning multifocus TEM images. The alignment process, comprising keypoint (based on scale-invariant feature transform, SIFT) and intensity matching, significantly mitigates the adverse effects of perceived motion-induced image degradation during through-focal TEM imaging, directly enhancing INR-TEM’s detection capability over conventional single-focus images. Our integrated INR-TEM cavity detection framework notably improves performance across various cavity sizes, outperforming off-the-shelf YOLOv8 detections that rely on a single image modality.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Real-time kinematic (RTK) Drone-collected Data and Processed Models of Port Arthur Coastal Neighborhood and Pleasure Island Golf Course, June 2024

The Southeast Texas Urban Integrated field lab’s Co-design team captured aerial photos in the Port Arthur Coastal Neighborhood Community and the Golf Course on Pleasure Island, Texas, in June 2024. Aerial photos taken were through autonomous flight, and models were processed through the DroneDeploy engine. All aerial photos are in .JPG format and contained in zipped files for each area. The processed data package includes 3D models, geospatial data, mappings, and point clouds. Please be aware that DTM, Elevation toolbox, Point Cloud, and Orthomosaic use EPSG: 6588. And 3D Model uses EPSG: 3857.For using these data:- The Adobe Suite gives you great software to open .Tif files.- You can use LASUtility (Windows), ESRI ArcGIS Pro (Windows), or Blaze3D (Windows, Linux) to open a LAS file and view the data it contains.- Open an .OBJ file with a large number of free and commercial applications. Some examples include Microsoft 3D Builder, Apple Preview, Blender, and Autodesk.- You may use ArcGIS, Merkaartor, Blender (with the Google Earth Importer plug-in), Global Mapper, and Marble to open .KML files.- The .tfw world file is a text file used to georeference the GeoTIFF raster images, like the orthomosaic and the DSM. You need suitable software like ArcView to open a .TFW file.This dataset provides researchers with sufficient geometric data and the status quo of the land surface at the locations mentioned above. This dataset will support researchers' decision-making processes under uncertainties.

2D mapping↗
NASA NTRS1990

The application of CFD to rotary wing flow problems

Rotorcraft aerodynamics is especially rich in unsolved problems, and for this reason the need for independent computational and experimental studies is great. Three-dimensional unsteady, nonlinear potential methods are becoming fast enough to enable their use in parametric design studies. At present, combined CAMRAD/FPR analyses for a complete trimmed rotor soltution can be performed in about an hour on a CRAY Y-MP (or ten minutes, with multiple processors). These computational speeds indicate that in the near future many of the large CFD problems will no longer require a supercomputer. The ability to convect circulation is routine for integral methods, but only recently was it discovered how to do the same with differential methods. It is clear that the differential CFD rotor analyses are poised to enter the engineering workplace. Integral methods already constitute a mainstay. Ultimately, it is the users who will integrate CFD into the entire engineering process and provide a new measure of confidence in design and analysis. It should be recognized that the above classes of analyses do not include several major limiting phenomena which will continue to require empirical treatment because of computational time constraints and limited physical understanding. Such empirical treatment should be included, however, into the developing CFD, engineering level analyses. It is likely that properly constructed flow models containing corrections from physical testing will be able to fill in unavoidable gaps in the experimental data base, both for basic studies and for specific configuration testing. For these kinds of applications, computational cost is not an issue. Finally, it should be recognized that although rotorcraft are probably the most complex of aircraft, the rotorcraft engineering community is very small compared to the fixed-wing community. Likewise, rotorcraft CFD resources can never achieve fixed-wing proportions and must be used wisely. Therefore the fixed-wing work must be gleaned for many of the basic methods.

Caradonna, F. X.↗
NASA NTRS1999

Multidisciplinary Optimization Branch Experience Using iSIGHT Software

The Multidisciplinary Optimization (MDO) Branch at NASA Langley Research Center is investigating frameworks for supporting multidisciplinary analysis and optimization research. An optimization framework call improve the design process while reducing time and costs. A framework provides software and system services to integrate computational tasks and allows the researcher to concentrate more on the application and less on the programming details. A framework also provides a common working environment and a full range of optimization tools, and so increases the productivity of multidisciplinary research teams. Finally, a framework enables staff members to develop applications for use by disciplinary experts in other organizations. Since the release of version 4.0, the MDO Branch has gained experience with the iSIGHT framework developed by Engineous Software, Inc. This paper describes experiences with four aerospace applications: (1) reusable launch vehicle sizing, (2) aerospike nozzle design, (3) low-noise rotorcraft trajectories, and (4) acoustic liner design. All applications have been successfully tested using the iSIGHT framework, except for the aerospike nozzle problem, which is in progress. Brief overviews of each problem are provided. The problem descriptions include the number and type of disciplinary codes, as well as all estimate of the multidisciplinary analysis execution time. In addition, the optimization methods, objective functions, design variables, and design constraints are described for each problem. Discussions on the experience gained and lessons learned are provided for each problem. These discussions include the advantages and disadvantages of using the iSIGHT framework for each case as well as the ease of use of various advanced features. Potential areas of improvement are identified.

Padula, S. L.↗
DOE OSTI2020

U.S. Domestic Small Modular Reactor Security by Design

U.S. nuclear power facilities face increasing challenges in meeting evolving security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The addition of security features after a facility has been designed and without attention to optimization (the past approach) can lead to cost overruns. Incorporating security in the design process can provide robust, cost effective, and sufficient physical protection systems. The purpose of this work is to develop a framework for the integration of security into the design phase of Small Modular Reactors (SMRs) and the use of modeling and simulation tools to optimize the design of physical protection systems. This effort will intend to integrate security into the design phase of a model SMR that meets current NRC physical protection requirements and provide advanced solutions to improve physical protection and decrease costs. A suite of tools, including SCRIBE3D, PATHTRACE and Blender were used to model a hypothetical generic domestic SMR facility. Physical protection elements such as sensors, cameras, portal monitors, barriers, and guard forces were added to the model based on best practices for physical protection systems. One outsider sabotage scenario was examined with 4-8 adversaries to determine security metrics. This work will influence physical protection system designs and facility designs for U.S. domestic SMRs. The purpose of this project is to demonstrate how a series of experimental and modeling capabilities across the Department of Energy Complex can impact the design of U.S. domestic SMRs and the complete Safeguards and Security by Design (SSBD) for SMRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Topographic hydro-conditioning to resolve surface depression storage and ponding in a fully distributed hydrologic model

Land surface depressions play a central role in the transformation of rainfall to ponding, infiltration and runoff, yet digital elevation models (DEMs) used by spatially distributed hydrologic models that resolve land surface processes rarely capture land surface depressions at spatial scales relevant to this transformation. Methods to generate DEMs through processing of remote sensing data, such as optical and light detection and ranging (LiDAR) have favored surfaces without depressions to avoid adverse slopes that are problematic for many hydrologic routing methods. Here, in this study, we present a new topographic conditioning workflow, Depression-Preserved DEM Processing (D2P) algorithm, which is designed to preserve physically meaningful surface depressions for depression-integrated and efficient hydrologic modeling. D2P includes several features: (1) an adaptive screening interval for delineation of depressions, (2) the ability to filter out anthropogenic land surface features (e.g., bridges), (3) the ability to blend river smoothing (e.g., a general downslope profile) and depression resolving functionality. From a case study in the Goodwin Creek Experimental Watershed, D2P successfully resolved 86% of the ponds at a DEM resolution of 10 m. Topographic conditioning was achieved with minimum impact as D2P reduced the number of modified cells from the original DEM by 51% compared to a conventional algorithm. Furthermore, hydrologic simulation using a D2P processed DEM resulted in a more robust characterization on surface water dynamics based on higher surface water storage as well as an attenuated and delayed peak streamflow.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2012

An Integrated Tool for System Analysis of Sample Return Vehicles

The next important step in space exploration is the return of sample materials from extraterrestrial locations to Earth for analysis. Most mission concepts that return sample material to Earth share one common element: an Earth entry vehicle. The analysis and design of entry vehicles is multidisciplinary in nature, requiring the application of mass sizing, flight mechanics, aerodynamics, aerothermodynamics, thermal analysis, structural analysis, and impact analysis tools. Integration of a multidisciplinary problem is a challenging task; the execution process and data transfer among disciplines should be automated and consistent. This paper describes an integrated analysis tool for the design and sizing of an Earth entry vehicle. The current tool includes the following disciplines: mass sizing, flight mechanics, aerodynamics, aerothermodynamics, and impact analysis tools. Python and Java languages are used for integration. Results are presented and compared with the results from previous studies.

Samareh, Jamshid A.↗
DOE OSTI2024

Reference Piping and Instrumentation Diagrams for Heat Transport Systems for Methanol Plants

This report aims to bridge the gap between advanced nuclear reactor vendors and methanol producers seeking decarbonization. It equips both parties with tools and preliminary information for integrating clean heat from advanced reactors into novel methanol production processes. The proposed investigation in this report involves a three-step approach: 1. Design of Current and Decarbonized Process Models for Methanol Production. This report initiates process modeling of two novel methanol production pathways, with their overall energy requirements comparative to classical methanol production (see Figure ES1). The two process models provide the foundation for analyzing integration of hermos-electric generation from advanced nuclear reactors. 2. Identification of Coupling Points to Integrate Advanced Reactors. This report investigates the integration with two advanced reactor technologies: light-water reactors (LWRs) and high-temperature gas reactors (HTGRs). The key coupling points between advanced nuclear reactors and the production facilities associated with the two decarbonized methanol process pathways are identified. 3. Preliminary Heat and Electricity Transfer Design from Reactors to Methanol Production Sites. The preliminary designs for piping and instrumentation to transfer heat from the boundary of advanced reactor technology location to the boundary of methanol production site are evaluated within the context of decarbonized pathways. The pipe analysis for heat transfer adheres to relevant codes and specifications from American Society of Mechanical Engineering. A simplified design for transmission of electricity to the industrial site has been provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗