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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Electron Beam Freeform Fabrication: A Rapid Metal Deposition Process

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley REsearch Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Thus far, this technique has been demonstrated on aluminum and titanium alloys of interest for aerospace structural applications nickel and ferrous based alloys are also planned. Deposits resulting from 2219 aluminum demonstrations have exhibited a range of grain morphologies depending upon the deposition parameters. These materials ave exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF process is capable of bulk metal deposition at deposition rated in excess of 2500 cubic centimeters per hour (150 cubic inches per our) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M. B.↗
NASA NTRS2006

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗
NASA NTRS2006

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗
NASA NTRSDate not supplied

Laser-Processed Condensing Heat Exchanger for Space Applications

In sizing a condensing heat exchanger for space life support systems, there is a limit to allowable pressure drop along with a required vapor recuperation rate. This sizing is performed by using known heat transfer and pressure drop correlations in a numerical model. Dimpling the surface of an air-liquid channeled heat exchanger increases the convective heat transfer rate however creates difficulties within the numerical model as the flat plate correlations are no longer accurate. To increase the fidelity of the numerical model used for sizing the heat exchanger Computational Fluid Dynamics (CFD) with an SST k-ω turbulence model was performed on a periodic portion of the heat exchanger. Through CFD modeling a heat flux and pressure drop was measured across the heat exchanger channel, this information was used to create a localized Nusselt number that was incorporated into the numerical model along with a more accurate pressure drop due to the dimpled surface. Additionally, through modeling the heat exchanger after manufacturing and assembly in Computer Aided Drafting (CAD) software there was an increase in the measurement accuracy of geometric features which was incorporated into the numerical model for further increase in fidelity.

heat exchanger↗
DOE OSTI2025

Grid Value Analysis of Geothermal Systems for End-Use Applications

Fuel based end-uses for residential, commercial, and industrial consumers require a technology change to achieve economy-wide decarbonization. Space heating accounts for 42% of residential and 32% of commercial energy demand, much of which is currently met through carbon emitting fuels. Industrial energy use is heavily fuel based with electricity currently representing 13% of energy demand. Geothermal heat pumps (GHPs) and geothermal direct use can eliminate the need for CO2 emitting and simultaneously allow for more efficient electrification of end uses. Past work has assessed the impact on total energy costs and generation investments but did not identify specific grid services benefited. Energy usage in residential and commercial structures was assessed by leveraging data from ComStock and ResStock models. These models utilize housing attributes, occupancy patterns, weather data, and sophisticated energy simulations to generate hourly load profiles for individual buildings identified by unique IDs associated with their locations. Industrial sector energy use was evaluated using information from the Manufacturing Energy Consumption Survey (MECS) as well as plant utilization data from the US Census to estimate hourly plant operations. The change in end-use demand for electricity, natural gas, and other fuels was calculated for different technologies that could meet this need. Using the ReEDS capacity expansion model, we produce regional price profiles that capture the grid benefit associated with the amount and timing of energy shifts in the power system from the adoption of geothermal systems relative to other technologies that could meet space heating, space cooling, and process heat requirements. We find that geothermal systems for meeting end-use demand add value to the energy system. In buildings where geothermal systems increase grid costs, these values are offset by reduced fuel costs and benefits to externalities, including emissions and health impacts.

decarbonization↗
DOE OSTI2024

High Temperature Heat Pumps and Their Roles in the Decarbonization of Building and Industry

Heat pumps have been sought as a promising technology for air and water heating processes in buildings. Several OEMs have been commercializing heat pumps with varying capacities; However, the application has been limited to lower temperatures (less than 70℃). With the recently growing interest in replacing gas-fired equipment for buildings and industrial processes, a new class of heat pumps, known as high-temperature heat pumps, is gaining substantial interest where the target temperatures are higher than the conventional heat pump technology (greater than 90℃). The current study is focused on this class of heat pumps and aims to provide a holistic overview of state-of-the-art technology while highlighting major challenges and opportunities. The discussion will be focused on the availability of technology to enable higher sink temperatures, deployment-based applications, waste heat recovery, and process integration and controls.

Nawaz, Kashif↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage (CRADA Report)

NREL and Element 16 collaborated on sulfur thermal energy storage modeling using NREL’s high performance computing (HPC) resources to assist its application in industrial processes. Industrial process heat (IPH) accounts for ~70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately, 1500 TWht (~60% Terawatt hour thermal) of IPH demand is in the temperature range of 100-300°C. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. This HPC4EI project facilitated Element 16’s development of low-cost and high-impact molten sulfur TES for dispatchable IPH. The development of a high-fidelity model validated by experimental data and HPC simulations enabled the successful resolution of the complex interplay between fluid dynamics and heat transfer processes during transient operation of sulfur TES, overcoming the numerical challenges posed by the non-linear temperature-dependent physical properties of sulfur. The project helped accelerate Element 16’s molten sulfur TES product design and support its broad applications.

25 ENERGY STORAGE↗
NASA NTRS1976

Aerodynamic heat transfer to a hypersonic research aircraft model /X-24C/ at Mach 6

The paper reports on results of heat-transfer tests conducted on a 1/29-scale model of the X-24C-12I hypersonic research aircraft configuration in a Mach 6 tunnel at a Reynolds number of thirteen million using the phase-change heat transfer technique. Sequences of phase-change heat transfer pattern photographs are presented showing windward side and leeward side heating processes. Theoretical predictions of dimensionless heat transfer coefficients along a data line on lower fuselage and on fuselage side bracket the experimental values. A turbulent heating theory gives good agreement with data when shifted to a new virtual origin.

Lawing, P. L.↗
NASA NTRS2018

Robotic Asteroid Prospector (RAP)

This report presents the results from the nine-month, Phase 1 investigation for the Robotic Asteroid Prospector (RAP). This project investigated several aspects of developing an asteroid mining mission. It conceived a Space Infrastructure Framework that would create a demand for in space-produced resources. The resources identified as potentially feasible in the near-term were water and platinum group metals. The project's mission design stages spacecraft from an Earth Moon Lagrange (EML) point and returns them to an EML. The spacecraft's distinguishing design feature is its solar thermal propulsion system (STP) that can provide for three functions:propulsive thrust, process heat for mining and mineral processing, and electricity. The preferred propellant is water since this would allow the spacecraft to refuel at an asteroid for its return voyage to Cis-Lunar space thus reducing the mass that must be staged out of the EML point.The spacecraft will rendezvous with an asteroid at its pole, match rotation rate, and attach to begin mining operations. The team conducted an experiment in extracting and distilling water from frozen regolith simulant.

Cohen, Marc↗
DOE OSTI2025

Identification of Important Phenomena for Light Water Reactors During Heat Transport System Failure Events in Integrated Energy Systems

This work adapts historical literature and existing phenomena identification and ranking tables (PIRT) to be applicable to a novel nuclear power plant (NPP) and chemical or thermal process integrated energy system (IES), particularly focusing on the process heat and heat transport system failure events that are not a concern during normal NPP operation but become vital when an IES is considered. Nuclear energy has been suggested to go beyond base-load applications and be used for hydrogen co-generation systems, amongst other IESs. Prior to the implementation of nuclear IESs, sufficient analysis must be performed on accident events to ensure public safety. The events considered were deemed important because of their potential to damage systems, structures, and components (SSCs). Process thermal events of concern include loss of heat load and temperature transient events. Loss of heat load events were characterized as having high importance and being well understood. Temperature transient events may be further categorized by the cyclic loading and harmonics phenomena. Cyclic loading issues were classified as medium to high importance with knowledge gaps existing regarding fatigue and low power operation, while harmonics phenomena were classified as low importance and are well understood. Heat transport system failure events of concern include intermediate and process heat exchanger failures, mass addition to reactor coolant, ingress of material from thermal manifold/energy storage, and loss of intermediate fluid. Furthermore, these events tended to be of high or medium importance, with some knowledge gaps needing to be filled for individual reactor systems due to unique designs.

Integrated Energy System (IES)↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage

Industrial process heating (IPH) accounts for approximately 70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately 1500 TWht (approximately 60%) of IPH demand is in the temperature range of 100-300. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. TES development has historically been dominated by technologies suitable for deployment with concentrating solar power (CSP). State-of-the-art thermal storage deployed commercially with power tower CSP plants uses a 60%/40% NaNO3/KNO3 molten salt and operates between temperatures of approximately 280 degrees Celsius and 570 degrees Celsius using a two-tank configuration. However, these nitrate salts are unsuitable for operation outside of this temperature range due to a high freezing point of approximately 220 degrees Celsius, and limits on high-temperature salt stability and corrosion resistance of containment alloys. Other materials being investigated for TES include those based on: (1) sensible energy storage (various molten salt compositions, inert solid particles, rocks or pebble beds, sulfur, water, concrete, graphite, etc.), (2) latent energy storage in materials that undergo solid-liquid phase change at relevant temperatures (organic materials for low-temperature applications, inorganic salts and/or metals for high-temperature applications), or (3) thermochemical energy storage (hydrides, hydroxides, carbonates, metal oxides, etc.). The application temperature and challenges pertaining to storage material and/or containment cost, energy density, long-term thermal and cyclic stability, and charge/discharge heat transfer effectiveness drive material selection for a given IPH or electricity generation application. Sulfur is a cheap commodity at $80/ton compared to $1100 - 1300/ton for conventional salts. When using a metric of storage cost per kWh, sulfur costs around 2-3 $/kWh. Previous sulfur TES development focused on high temperature (>600 degrees) concentrated solar power applications with sulfur encapsulated in pipes and flow of gaseous HTF (air) in the shell side. However, for lower-temperature IPH applications in the range of approximately 100-300 degrees Celsius Element 16 adopted a compact and scalable TES design with molten sulfur in the shell and HTF pipes submerged in the molten sulfur bath. The low-cost molten sulfur TES for dispatchable IPH has deployment potential for broad applications. The spatial and temporal evolution of the HTF and sulfur temperature is critical to the TES system performance, and thus detailed modeling can improve understanding of the performance and facilitate design improvements. Using high performance computing and computational fluid dynamics (CFD) a low-cost molten sulfur thermal energy storage (TES) system for industrial process heating (IPH) applications was developed. The unique challenges in CFD modeling of sulfur TES are the sharp property changes of sulfur relevant to the working temperatures. Above 159, liquid sulfur undergoes polymerization, and the viscosity of sulfur rapidly increases by several orders of magnitude between 159 degrees Celsius and 188 degrees Celsius, followed by a decrease in viscosity beyond 188 degrees Celsius due to thermal bound dissociation. In addition, various concentrations of H2S impurities can also modify sulfur viscosity. This numerical challenge is especially relevant to transient simulation of the sulfur TES charging and discharging processes as the extreme property variations limit the applicability of traditional heat transfer correlations. Transient CFD simulations including the temperature-dependent sulfur properties and geometric complexity of the TES design were used to predict the effect of natural convection during charging and discharging on the heat transfer process, sulfur temperature uniformity, charge/discharge rates, and performance of the storage devices. The CFD model was validated with experimental results for a full charge and discharge cycle. The work will show 3D and 2D simulation comparisons aimed to facilitate rapid design iterations and a machine learning based design optimization approach.

CFD↗
DOE OSTI2026

First Solar Thermal Energy Planner (STEP 1) and Nationwide Industrial Heat and Power Analysis

The First Solar Thermal Energy Planner (STEP 1) and Nationwide Industrial Heat and Power Analysis (aka the STEP 1 Project or the Project) aimed to (1) developed a brand-new web tool that could provide decision support through free, rapid techno-economic analysis of behind-the-meter solar+storage systems for industrial process heat and (2) conduct high-level analyses of the cost-competitiveness of the same systems across the US in key sectors. The STEP 1 web tool collects key location, land availability, thermal load profile, proccess heat temperature and media, and other key parameters through an easy-to-use user interface (UI). The UI was designed to meet the user at their level of understanding by minimizing the number of required inputs as much as possible while including options for more nuanced inputs if the user desires. STEP 1 advises users on which solar thermal tehcnologies that could fit their needs based on the inputs provided (namely process media and temperature). The tool can model a wide range of solar thermal technologies including flat plate collectors, evacuated tubes, parabolic troughs, linear Fresnel, and molten salt towers all with corresponding thermal energy storage (TES) - solar PV with resistive heating and TES is also included. Once the parameters are collected, a nominal thermal energy production profile for the facility's location is generated using NREL's System Advisory Model (SAM) and then passed to a modified version of NREL's REopt platform to optimize the size (capacity) and dispatch of the solar+storage system to minimize lifecycle costs subject to energy balance, fuel and electricity rates, emission reductions goals, and other constraints. This entire process takes less than 20 minutes, is completely free, requires zero coding skills, and provides the user with a high-level assessment on the techno-economic feasability of deploying solar+storage systems for their energy needs. In addition to the development of the STEP 1 web tool, the project completed two complementary analyses focused on leveraging the backend code of STEP 1, public industrial facility locations and fuel consumption data, and key sector information to assess the economic opportunity of reducing fuel costs at various levels of capacity factor around the US. Both analyses found that there are key markets, locations, industrial sectors (namely food and beverage), and degrees of offset where solar thermal technologies could be cost-effectively deployed, highlighting a key market entry point for these technologies, and assessing deployment potential. In summary, the STEP 1 project improved the opportunities for solar+storage systems to expand into the industrial process heat market through breaking down barriers to assessing these technologies.

14 SOLAR ENERGY↗
DOE OSTI2024

Field Validation of Electrochemical Water Filtration System on Open Loop Cooling Towers at Automotive Plants

Open loop cooling towers play a pivotal role in rejecting heat for chilled water systems serving industrial processes, heating, ventilation, and air conditioning loads. Exposure to outside conditions can present certain operating challenges to system performance including scaling, corrosion, and biological growth. These issues are mitigated through the use of effective cooling tower water filtration and treatment systems to reduce contaminants—along with other total suspended solids (TSS) and total dissolved solids (TDS)—in the system. The U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office is interested in an electrochemical-based filtration system with the ability to remove TSS particulate down to 1 micron. The removal of finer particulates reduces the need for blowdown and, in turn, makeup water use and chemical treatment in the cooling tower. Additionally, the removal process can reduce fouling at the condensers, resulting in better heat exchange and energy savings. Two Industrial Technology Validation program projects validated the electrochemical water filtration system at the Toyota Motor Manufacturing, Mississippi plant in Blue Springs, Mississippi, and the Nissan Canton Vehicle Assembly Plant in Canton, Mississippi. Researchers found that installation of both systems resulted in water and chemical treatment savings with minimal impact on energy use.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1976

Nuclear driven water decomposition plant for hydrogen production

The conceptual design of a hydrogen production plant using a very-high-temperature nuclear reactor (VHTR) to energize a hybrid electrolytic-thermochemical system for water decomposition has been prepared. A graphite-moderated helium-cooled VHTR is used to produce 1850 F gas for electric power generation and 1600 F process heat for the water-decomposition process which uses sulfur compounds and promises performance superior to normal water electrolysis or other published thermochemical processes. The combined cycle operates at an overall thermal efficiency in excess of 45%, and the overall economics of hydrogen production by this plant have been evaluated predicated on a consistent set of economic ground rules. The conceptual design and evaluation efforts have indicated that development of this type of nuclear-driven water-decomposition plant will permit large-scale economic generation of hydrogen in the 1990s.

Parker, G. H.↗
NASA NTRS1996

Thermal Excitation System for Shearography (TESS)

One of the most convenient and effective methods of stressing a part or structure for shearographic evaluation is thermal excitation. This technique involves heating the part, often convectively with a heat gun, and then monitoring with a shearography device the deformation during cooling. For a composite specimen, unbonds, delaminations, inclusions, or matrix cracking will deform during cooling differently than other more structurally sound regions and thus will appear as anomalies in the deformation field. However, one of the difficulties that cause this inspection to be dependent on the operator experience is the conventional heating process. Fanning the part with a heat gun by hand introduces a wide range of variability from person to person and from one inspection to the next. The goal of this research effort was to conduct research in the methods of thermal excitation for shearography inspection. A computerized heating system was developed for inspection of 0.61 m (24 in.) square panels. The Thermal Excitation System for Shearography (TESS) provides radiant heating with continuous digital measurement of the surface temperature profile to ensure repeatability. The TESS device functions as an accessory to any electronic shearography device.

Lansing, Matthew D.↗
NASA NTRS1978

Thermal resistance of naturally occurring airborne bacterial spores

Simulation of a heat process used in the terminal dry-heat decontamination of the Viking spacecraft is reported. Naturally occurring airborne bacterial spores were collected on Teflon ribbons in selected spacecraft assembly areas and subsequently subjected to dry heat. Thermal inactivation experiments were conducted at 105, 111.7, 120, 125, 130, and 135 C with a moisture level of 1.2 mg of water per liter. Heat survivors were recovered at temperatures of 135 C when a 30-h heating cycle was employed. Survivors were recovered from all cycles studied and randomly selected for identification. The naturally occurring spore population was reduced an average of 2.2 to 4.4 log cycles from 105 to 135 C. Heating cycles of 5 and 15 h at temperature were compared with the standard 30-h cycle at 111.7, 120, and 125 C. No significant differences in inactivation (alpha = 0.05) were observed between 111.7 and 120 C. The 30-h cycle differs from the 5- and 15-h cycles at 125 C. Thus, the heating cycle can be reduced if a small fraction (about 0.001 to 0.0001) of very resistant spores can be tolerated.

Puleo, J. R.↗