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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
DOE OSTI2015

Hydrodynamic Effects on Modeling and Control of a High Temperature Active Magnetic Bearing Pump with a Canned Rotor

Embedding instrumentation and control Embedding instrumentation and control (I\&C) at the component level in nuclear power plants can improve component performance, lifetime, and resilience by optimizing operation, reducing the constraints on physical design, and providing on-board prognostics and diagnostics. However, the extreme environments that many nuclear power plant components operate in makes embedding instrumentation and control at the component level difficult. Successfully utilizing embedded I\&C requires developing a deep understanding of the system's dynamics and using that knowledge to overcome material and physical limitations imposed by the environment. In this paper, we will develop a coupled dynamic model of a high temperature (700 $^\circ$C) canned rotor pump that incorporates rotordynamics, hydrodynamics, and active magnetic bearing dynamics. Then we will compare two control design methods, one that uses a simplified decoupled model of the system and another that utilizes the full coupled system model. It will be seen that utilizing all the available knowledge of the system dynamics in the controller design yield an order of magnitude improvement in the magnitude of the magnetic bearing response to disturbances at the same level of control effort, a large reduction in the settling time of the system, and a smoother control action.

Melin, Alexander M↗
DOE OSTI2019

Development of a High-Efficiency Hot Gas Turbo-expander and Low-Cost Heat Exchangers for Optimized CSP Supercritical CO 2 Operation

Southwest Research Institute® (SwRI®) has developed a novel, high-efficiency, supercritical carbon dioxide (sCO 2 ), hot gas turbo-expander optimized for the highly-transient, solar-powerplant, duty-cycle profile. This MW-scale sCO 2 turbo-expander design advances the state-of-theart of sCO 2 turbo-expanders from a current Technology Readiness Level (TRL) of three (initial, small-scale, laboratory, size testing) to a full TRL6 (MW-scale prototype demonstration). A secondary objective of this project was to optimize novel compact heat exchangers for sCO 2 applications to drastically reduce their manufacturing costs. Significant learning was achieved on how to design and fabricate a more cost effective, high performance recuperator, at the MWt capacity. The sCO 2 turbo-expander and novel sCO 2 heat exchanger have been tested in a 1- MWe sCO 2 test loop, fabricated to demonstrate component performance and the performance of the optimized sCO 2 Brayton cycle over a wide range of part load conditions and during transient operations representative of a typical Concentrating Solar Power (CSP) duty cycle. The scalable sCO 2 expander design and improved heat exchanger address and close two critical technology gaps required for an optimized CSP sCO 2 power plant and provide a major stepping stone on the pathway to achieving CSP power at $\$ $0.06/kW-hr Levelized Cost of Electricity (LCOE), increasing energy conversion efficiency to greater than 50% and reducing total power block cost to below $\$ $1,200/kW installed. Construction of the facility and testing has been completed. Test targets of 1,320°F, 27,000 rpm, and 3,500 psi were reached during separate tests. Overall, the turbine saw 37.5 hours of operation with many other hours of testing and troubleshooting all of the loop components. All the test data and troubleshooting is useful and applicable for future tests and operations with not only this loop but in any sCO2 application.

14 SOLAR ENERGY↗
DOE OSTI2018

An Analysis of Advanced Manufacturing for Innovative Burner Nozzle Design

Utilizing the Arcam electron beam melting powder bed process, fuel nozzles designed by GTI and not manufacturable by traditional manufacturing techniques were produced. The fuel nozzles resulted in a 50% reduction in emissions and efficiency improvement. The goal of this project was to assess the cost and performance benefits of utilizing selected Additive Manufacturing (AM) approaches to fabricate an advanced premix nozzle for use in commercial burner applications that can only be manufactured by advanced AM methods, and which offers the potential for increased component performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Investigating Machine Learning Based X-Ray Computed Tomography Reconstruction Methods to Enhance the Accuracy of CT Scans

Development of new materials and predictive capabilities of component performance hinges on the ability to accurately digitize "as-built" geometries. X-ray computed tomography (CT) offers a non-destructive method of capturing these details but current methodologies are unable to produce the required fidelity for critical component certification. This project focused on discovering the limitations of existing CT reconstruction algorithms and exploring machine learning (ML) methodologies to overcome these limitations. We found that existing CT reconstruction methods are insufficient for Sandia's critical component certification process and that ML algorithms are a viable path forward to improving the quality of CT images.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

CMB-S4: Iterative Internal Delensing and r Constraints

Abstract The tightest constraints on the tensor-to-scalar ratio r can only be obtained after removing a substantial fraction of the lensing B -mode sample variance. The planned Cosmic Microwave Background (CMB)-S4 experiment ( cmb-s4.org ) will remove the lensing B -mode signal internally by reconstructing the gravitational lenses from high-resolution observations. We document here a first lensing reconstruction pipeline able to achieve this optimally for arbitrary sky coverage. We make it part of a map-based framework to test CMB-S4 delensing performance and its constraining power on r , including inhomogeneous noise and two non-Gaussian Galactic polarized foreground models. The framework performs component separation of the high-resolution maps, followed by the construction of lensing B -mode templates, which are then included in a parametric small-aperture map cross-spectra-based likelihood for r . We find that the lensing reconstruction and framework achieve the expected performance, compatible with the target σ ( r ) ≃ 5 · 10 −4 in the absence of a tensor signal, after an effective removal of 92%–93% of the lensing B -mode variance, depending on the simulation set. The code for the lensing reconstruction can also be used for cross-correlation studies with large-scale structures, lensing spectrum reconstruction, cluster lensing, or other CMB lensing-related purposes. As part of our tests, we also demonstrate the joint optimal reconstruction of the lensing potential with the lensing curl potential mode at second order in the density fluctuations.

Astronomy & Astrophysics↗
DOE OSTI2015

Measurement of neutron spectra in the experimental reactor LR-0

The measurement of fast neutron fluxes is important in many areas of nuclear technology. It affects the stability of the reactor structural components, performance of fuel, and also the fuel manner. The experiments performed at the LR-0 reactor were in the past focused on the measurement of neutron field far from the core, in reactor pressure vessel simulator or in biological shielding simulator. In the present the measurement in closer regions to core became more important, especially measurements in structural components like reactor baffle. This importance increases with both reactor power increase and also long term operation. Other important task is an increasing need for the measurement close to the fuel. The spectra near the fuel are aimed due to the planned measurements with the FLIBE salt, in FHR / MSR research, where one of the task is the measurement of the neutron spectra in it. In both types of experiments there is strong demand for high working count rate. The high count rate is caused mainly by high gamma background and by high fluxes. The fluxes in core or in its vicinity are relatively high to ensure safe reactor operation. This request is met in the digital spectroscopic apparatus. All experiments were realized in the LR-0 reactor. It is an extremely flexible light water zero-power research reactor, operated by the Research Center Rez (Czech Republic). (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Multiscale Solar Water Heating (MSWH) v1.0

The main purpose of the software is to model energy use for individual and community scale solar water heating projects in California. Usage The user provides a climate zone for a project, an occupancy for each household and whether any of the occupants stay at home during the day. The software can then load a set of example California specific hourly domestic hot water end-use load profiles from a database, size and locate the systems. The user can now simulate the hourly system performance over a period of one representative year, visualize and explore the simulation results using time-series plots for temperature profiles, heat and power rates, or look at annual summaries. Similarly the user can model individual household solar water heating projects and base case conventional gas tank water heater systems, such that the results can be compared between the individual, community and base case systems. This functionality is readily available through a Jupyter notebook and a Django web framework, depending on what level of detail the user would like to access. Features - Python module to calculate solar irradiation on a tilted surface - Python module with simplified component models for Converter (solar collectors, electric resistance heater, gas burner, photovoltaic panels, heat pump), Storage (solar thermal tank, heat pump thermal tank, conventional gas tank water heater), and Distribution (distribution and solar pump, piping losses) components - Python module with preconfigured system simulation models for: base case gas tank water heaters, solar thermal water heaters (solar collector feeding a storage tank, with a tankeless gas water heater backup in a new installation cases and a base case gas tank water heater in a retrofit case) and solar electric water heaters (heat pump storage tank with an electric resistance backup) - Database with component performance parameters, California specific weather data and domestic hot water end-use load profiles - Django web framework to configure project, parametrize components and run simulation from a web browser The package contains functional and unit tests and it is structured so that it can be extended with further technologies, applications and locations.

Grahovac, Milica↗
DOE OSTI2016

Final Report: Hydrogen Storage System Cost Analysis

The Fuel Cell Technologies Office (FCTO) has identified hydrogen storage as a key enabling technology for advancing hydrogen and fuel cell power technologies in transportation, stationary, and portable applications. Consequently, FCTO has established targets to chart the progress of developing and demonstrating viable hydrogen storage technologies for transportation and stationary applications. This cost assessment project supports the overall FCTO goals by identifying the current technology system components, performance levels, and manufacturing/assembly techniques most likely to lead to the lowest system storage cost. Furthermore, the project forecasts the cost of these systems at a variety of annual manufacturing rates to allow comparison to the overall 2017 and “Ultimate” DOE cost targets. The cost breakdown of the system components and manufacturing steps can then be used to guide future research and development (R&D) decisions. The project was led by Strategic Analysis Inc. (SA) and aided by Rajesh Ahluwalia and Thanh Hua from Argonne National Laboratory (ANL) and Lin Simpson at the National Renewable Energy Laboratory (NREL). Since SA coordinated the project activities of all three organizations, this report includes a technical description of all project activity. This report represents a summary of contract activities and findings under SA’s five year contract to the US Department of Energy (Award No. DE-EE0005253) and constitutes the “Final Scientific Report” deliverable. Project publications and presentations are listed in the Appendix.

08 HYDROGEN↗
DOE OSTI2024

Optimized Viewing Techniques to Minimize Radiation Damage From X-ray Imaging Systems

X-ray inspection of ball grid arrays (BGAs) is typically performed at one or more viewing angles to examine adhesion sites for errors such as voids, joint cracking, or head-in-pillow. During this inspection process, the cir cuit board assembly is subject to ionizing radiation exposure, which can cause trapped charge within oxide layers of semiconductor devices. Some x-ray machines allow for programmable inspection routines, which could be used to optimize radiation exposure to semiconductor components. Using Monte Carlo methods, x-ray inspection of a BGA was simulated to determine a range of acceptable viewing angles. Dose rates to circuit board components were estimated at each inspection angle to determine the view resulting in optimized radiation exposure. Results showed that for each BGA, the maximum unobstructed viewing times without exceeding a 5 Gy dose limit to a single part ranged from 82 to 94 minutes. Using a radiation cost function method, optimized viewing across all components was found. Here, it was observed that for a consistent dose limit applied to silicon-based components, performing inspection with BGAs facing the x-ray source was optimal. A third method was applied, assigning individual dose limits based on empirical data from the NASA Goddard Space Flight Center radiation database. This method showed that optimized viewing maximizes the distance between the radiation source and highly sensitive components. It was also observed that cumulative effects from viewing two BGAs will influence viewing angles, causing the optimal view of one BGA to exist nearly 180° from the other.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Multi-technique characterization of spray coated and roll-to-roll coated gas diffusion fuel cell electrodes

Here this work reports the characterization of catalyst layer (CL) structure and composition for a set of gas-diffusion electrodes (GDEs) fabricated by different coating methods with the goal of developing a better understanding of CL processing-structure-property-performance relationships. The CL coating techniques used in this study were ultrasonic spray coating, and two roll-to-roll (R2R) methods - gravure and slot die. Scanning transmission electron microscopy (STEM) coupled with X-ray energy dispersive spectroscopy (EDS) analysis of GDE cross-sections provided bulk information, while scanning electron microscopy (SEM) with EDS and X-ray photoelectron spectroscopy (XPS) were used to investigate the near surface and surface composition of the CLs that will be in direct contact with the membrane once the membrane electrode assembly (MEA) is constructed. This study demonstrates that common quantification parameters, namely the F:Pt ratio extracted from cross-sectional STEM-EDS maps and top-down CL measurements with SEM and XPS, along with roughness parameters quantified from SEM micrographs are useful parameters in explaining and potentially predicting performance trends. Additionally, it highlights the importance of understanding key CL surface properties for advancing the manufacturability of high-performance components for polymer electrolyte membrane (PEM) technologies.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Technical report Letter: RAFM, ODS steels and MMLC for Nuclear energy application

The lifetime, thermodynamic efficiency, safety and economic viability of new generation fission and fusion reactor concepts can largely be tied to the mechanical performance and stability of structural alloys under extreme environments. In this context, engineered nano materials could have broad-reaching impact on the future of advanced nuclear fuel-cycle and reactors. These systems are characterized by a large number density of interfaces which are efficient sinks for point defects and moderately biased; therefore limiting the deleterious effects of irradiation. Broadly, nuclear nano-technology deals with the use of the latest engineered-nanomaterials for improving the nuclear power performances and safety in all areas of nuclear energy production to bring new generations of nuclear power units. New advanced fuel assembly designs also have implications for securities and safeguards. To support the readiness for potential future license applications, an understanding of the technologies that would enable new reactor designs in the areas of component performance and domestic safeguards is necessary. This technical report letter work explores the technical issues and potential regulatory considerations associated with developing and adopting fuel claddings made of advanced nano- materials. Specifically three classes of nanomaterials are considered: (i) reduced activation ferritic/martensitic (RAFM) steels, (ii)oxide dispersed steels (ODS) and (iii) multi-metallic layered composites (MMLC).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A simplified approach for creep damage and remaining life calculation for materials surveillance in advanced reactors

High temperature reactor materials will experience a combination of mechanical degradation caused by creep and fatigue and environmental degradation caused by neutron irradiation and, in some cases, exposure to corrosive coolants. A materials surveillance program is one option for ensuring the safe, reliable operation of key reactor components under these conditions. Such a program would monitor the degradation in key material properties over time, using this data to predict how changes in the material properties affect components performance. This could then be used to make plant operational decisions and support eventual plant license extensions. Past work de-scribes such a material surveillance program based on passively actuated mechanical test articles that impose creep-fatigue type loading on test materials driven only by changes in temperature, for example those experienced by components under standard operating cycles. This report focuses on two aspects of the proposed material surveillance program: how to design the test articles to mimic the mechanical response of the corresponding component and how to use ex-situ test data to deter-mine the amount of damaged experienced by the test article (and hence the corresponding compo-nent) in service. Specifically, this report derives and validated simplified methods for both tasks, replacing earlier, more complicated approaches based on simulating the test article response and finding the best specimen design or current damage via complex numerical optimization. The sim-plified methods for each task developed here can be implemented in spreadsheet software and are simple enough for practical use in future operating plants. This report derives the methods (one for sizing and two options for damage inference), verifies the simplified approaches versus more so-phisticated methods, and compares the results of applying the simplified methods to previous re-sults using the complex numerical optimization approach. The report also provides a worked sam-pled problem applying the simplified techniques to a realistic high temperature reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Online and Offline Data Quality Monitoring for the Mu2e Calorimeter

This thesis presents the design, implementation, and validation of a calorimeter Data Quality Monitoring (DQM) toolchain for the Mu2e experiment at Fermilab. Mu2e searches for charged lepton flavor violation via coherent muon-to-electron conversion in the field of an aluminum nucleus, $\mu^- Al \rightarrow e^-Al$, a process whose observation would constitute clear evidence of physics beyond the Standard Model. Achieving target sensitivity requires stringent control of detector performance and data integrity during acquisition, as subtle issues in readout configuration, data formatting, or electronics behavior can compromise reconstruction and bias downstream analyzes. To address these challenges, this work develops a multi-layer DQM approach spanning both raw data validation and reconstructed digi-level diagnostics. At the low level, a fragment analysis component performs word- and bit-field decoding of calorimeter readout blocks, enabling sanity checks of the expected structure and producing detailed error and integrity statistics useful for commissioning and troubleshooting. At the digi level, the CaloDigiDQM analyzer is implemented within the art framework and transforms each CaloDigiCollection into a structured hierarchy of ROOT histograms designed for fast drill-down diagnostics. The module generates coherent monitoring views at global, disk, board, and channel granularity, including occupancy, waveform-derived features (baseline, RMS, peak amplitude and position), and left-right sensor consistency metrics. Detector-aware channel-to-electronics mapping is performed through the conditions system (CaloDAQMap), ensuring that diagnostics remain aligned with hardware identifiers used in operations. For end-to-end testing without reliance on live DAQ data, a synthetic CaloDigi producer is developed to generate realistic waveforms with controlled noise and pulse shapes. The resulting system supports both offline ROOT-file production and online operation, including optional histogram streaming through otsdaq via ots::HistoSender. This toolchain provides a practical and scalable foundation for calorimeter commissioning and stable data collection, enabling early detection of anomalies and reducing operational risk for Mu2e.

Vakulenko, Mark [Drew U.] (ORCID:0009000276197818)↗
DOE OSTI2025

Assessment of Heavy-Duty Fueling Methods and Components-Modeling and Analysis

The goal of the Assessment of Heavy-Duty Fueling Methods and Components project was to comprehensively assess heavy-duty (HD) fuel cell electric vehicle fueling protocols and their effects on techno-economic assessments (TEA) and total cost of ownership (TCO). The project leveraged and built upon ongoing international HD fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, TEA of industry-selected protocol structures, and experimental validations of the strategies at the station scale. The effects of the protocols on the fueling times, station costs, and TCO were explored. Fueling time, which was influenced by temperature and protocol selection, had a large impact on the station cost due to component sizing and satisfying hourly demand. As the fleet size increased, the station cost was shown to exponentially decrease by achieving economies of scale. Technology year and fuel economy were the largest contributors to the TCO; however, the choice of fueling protocol had a minor impact on the TCO.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Development and Evaluation of a Novel Fuel Injector Design Method using Hybrid-Additive Manufacturing (Final Report)

The widespread application of metal additive manufacturing (AM) technologies has enabled exploration of complex design spaces to achieve optimally performing components. Current optimization techniques make use of several advanced methods to provide designs that are superior to existing versions. However, they seldom discuss the manufacturability of the optimal designs. The objective of this project was to develop a design optimization tool that simultaneously optimizes fuel injector hardware and the combustor flow field with optimization functions and constraints that consider both combustor performance and manufacturability using advanced AM methods and post-processing. In this way, the resultant hardware design is inherently imbued with our most advanced knowledge of combustion physics and AM methods from its conception.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Advance High Temperature Inspection Capabilities for Small Modular Reactors: Part 1 - Ultrasonics

The project objective was to investigate the development non-destructive evaluation techniques for advanced small modular reactors (aSMR), where the research sought to provide key enabling inspection technologies needed to support the design and maintenance of reactor component performance. The project tasks for the development of inspection techniques to be applied to small modular reactor are being addressed through two related activities. The first is focused on high temperature ultrasonic transducers development (this report Part 1) and the second is focused on an advanced eddy current inspection capability (Part 2). For both inspection techniques the primary aim is to develop in-service inspection techniques that can be carried out under standby condition in a fast reactor at a temperature of approximately 250°C in the presence of liquid sodium. The piezoelectric material and the bonding between layers have been recognized as key factors fundamental for development of robust ultrasonic transducers. Dielectric constant characterization of bismuth scantanate-lead titanate ((1-x)BiScO 3 -xPbTiO 3 ) (BS-PT) has shown a high Curie temperature in excess of 450°C , suitable for hot stand-by inspection in liquid metal reactors. High temperature pulse-echo contact measurements have been performed with BS-PT bonded to 12.5 mm thick 1018-low carbon steel plate from 20C up to 260 C. High temperature air-backed immersion transducers have been developed with BS-PT, high temperature epoxy and quarter wavlength nickel plate, needed for wetting ability in liquid sodium. Ultrasonic immersion measurements have been performed in water up to 92C and in silicone oil up to 140C. Physics based models have been validated with room temperature experimental data with benchmark artifical defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Building America Case Study: Lancaster County Career and Technology Center Green Home 3, Mt Joy, Pennsylvania

Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction.This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate. Of primary interest is the influence of the ICF walls on developing an effective air sealing strategy and selecting an appropriate heating and cooling equipment type and capacity. The domestic water heating system is analyzed for costs and savings to investigate options for higher efficiency electric water heating. A method to ensure mechanical ventilation air flows is examined. The final solution package includes high-R mass walls, very low infiltration rates, multi-stage heat pump heating, solar thermal domestic hot water system, and energy recovery ventilation. This solution package can be used for homes to exceed 2012 International Energy Conservation Code requirements throughout all climate zones and achieves the DOE Challenge Home certification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗