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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Benchmark of numerical modeling approaches on the systematic performance evaluation of wave energy converters

Different numerical modeling methods have been developed and applied to evaluate a variety of performance indicators of wave energy converters (WECs), including the power performance, structural loads, levelized cost of energy, etc. Based on the modeling fidelity, the commonly used numerical modeling approaches can be classified as linear modeling, weakly nonlinear modeling and fully nonlinear modeling approaches. Each method differs in accuracy and computational efficiency, making them suitable for different stages of WEC design. However, the selection of modeling approach could significantly impact evaluation outcomes. For instance, simplified linear models may underestimate structural loads or overestimate energy production in some operational conditions, potentially leading to less cost-effective designs. Given the widespread utilization of these models, it is essential to understand the uncertainties brought by them in performance evaluations. This work is dedicated to benchmarking different linear-potential-flow-based numerical models for evaluating the systematic performance of WECs. Three representative numerical modeling approaches are considered in this work, including linear frequency-domain modeling, statistically linearized spectral-domain modeling and Cummins equation-based nonlinear time-domain modeling. A generic point absorber WEC is considered as the research reference in this work, and different sea sites are taken into account. The numerical models are utilized to predict critical performance indicators, including power performance, the annual energy production, the capacity factor, the levelized cost of energy and the PTO fatigue loads. By comparing the results, this work identifies the uncertainties associated with different modeling approaches in evaluating WEC performance.

Fatigue↗
DOE OSTI2021

Quantitative Non-Destructive Evaluation of Fatigue Damage Based on Multi-Sensor Fusion

Based on sensor fusion and machine learning, this project developed a novel non-destructive evaluation (NDE) methodology, which consists of a remaining useful life (RUL) prediction framework and regression models for predicting residual stress and full width at half maximum (FWHM). A series of fatigue testing experiments were conducted using 5052-H32 aluminum alloy specimens. All specimens were measured using linear ultrasonic (LU) and nonlinear ultrasonic (NLU) testing methods non-destructively. Machine learning models were developed to use LU and NLU measurements to predict loading condition, fatigue level, residual stress, and FWHM. It was demonstrated that the developed methodology could distinguish new and fatigue specimens with an accuracy of 97.53%. Also, the prediction errors for residual stress and FWHM were as low as 4.73% and 1.62%, respectively. An interactive database was created to publicly share the data generated from the project. It is envisioned that the developed NDE technology will equip manufacturers with a responsive screening system for incoming used metallic components, and potentially lead to a significant increase in using used metallic components for remanufacturing.

42 ENGINEERING↗
DOE OSTI2021

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades).

36 MATERIALS SCIENCE↗
DOE OSTI2020

Notch insensitivity in fatigue failure of chopped carbon fiber chip-reinforced composites using experimental and computational analysis

This study focuses on the notch effect on the fatigue failure of chopped carbon fiber chip-reinforced sheet molding compound (SMC) composites by using both experimental and numerical methods. The S-N diagrams of notched specimens are first obtained experimentally, which exhibit large scatter and are shown to depend on the spatial distribution of local fiber orientations. After considering the effect of this spatial distribution by adopting a new fatigue damage parameter to normalize the results, we achieve a much better correlation in the normalized S-N diagram for all the notched specimens with different hole diameters. Next, compared with the fatigue results of smooth specimens without notches, we find that SMC composites under tension-tension fatigue loading exhibit notch-insensitivity, which renders this type of composites a better candidate in joints or similar applications. Meanwhile, the fatigue failure mechanisms of notched SMC composites are explored through a microstructure characterization procedure. On this basis, a computational micromechanics model considering the notch effect and an improved multi-scale progressive damage fatigue law, calibrated by coupon-level fatigue tests of smooth SMC composites under different loading conditions, are employed to predict the fatigue behavior of notched SMC composites. We show that detailed failure processes and fatigue life of notched SMC composites can be efficiently and adequately predicted by this computational framework.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Predictive models of long COVID

Background: The cause and symptoms of long COVID are poorly understood. It is challenging to predict whether a given COVID-19 patient will develop long COVID in the future. Methods: We used electronic health record (EHR) data from the National COVID Cohort Collaborative to predict the incidence of long COVID. We trained two machine learning (ML) models — logistic regression (LR) and random forest (RF). Features used to train predictors included symptoms and drugs ordered during acute infection, measures of COVID-19 treatment, pre-COVID comorbidities, and demographic information. We assigned the ‘long COVID’ label to patients diagnosed with the U09.9 ICD10-CM code. The cohorts included patients with (a) EHRs reported from data partners using U09.9 ICD10-CM code and (b) at least one EHR in each feature category. We analysed three cohorts: all patients (n = 2,190,579; diagnosed with long COVID = 17,036), inpatients (149,319; 3,295), and outpatients (2,041,260; 13,741). Findings: LR and RF models yielded median AUROC of 0.76 and 0.75, respectively. Ablation study revealed that drugs had the highest influence on the prediction task. The SHAP method identified age, gender, cough, fatigue, albuterol, obesity, diabetes, and chronic lung disease as explanatory features. Models trained on data from one N3C partner and tested on data from the other partners had average AUROC of 0.75. Interpretation: ML-based classification using EHR information from the acute infection period is effective in predicting long COVID. SHAP methods identified important features for prediction. Cross-site analysis demonstrated the generalizability of the proposed methodology.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Compact Diffusion Bonded Heat Exchanger Fatigue Life Simulations (Final Report)

Compact diffusion bonded heat exchangers are essential for high pressure heat exchange, but they are subject to thermal fatigue and ramp rate limitations. Simulation of these geometries is challenging with a large range of length and time scales from thousands of mm-sized microchannels inside a m-sized heat exchanger. Multi-physics simulations including thermal, fluid, and solid mechanics components are being used to predict stress within the heat exchangers under these conditions. These predictions can then be used to understand thermal ramp rate limitations while keeping maximum stresses low as well as fatigue life predictions from well-known empirical models.

42 ENGINEERING↗
DOE OSTI2023

Enhancing Lithium-Ion Battery Aging Simulations: Coupling a High-Resolution, 3D, Grain-Scale Electromechanical Model to a Single-Particle Model

One of the main goals in modeling lithium-ion batteries is to improve/predict longevity and resilience of new chemistries. Unfortunately, this requires simulation of thousands of charge/discharge cycles, which can be rather time consuming depending on the fidelity of the simulation. The purpose of this talk is to discuss a new modeling framework that couples a high-resolution, continuous damage model (CDM) to a single particle model (SPM) resulting in a good combination of speed and fidelity. In previous work, a 3D, continuum-level chemo-mechanical model was developed to investigate cracking within a single cathode particle comprised of hundreds to thousands of randomly oriented grains. The CDM predicted that particle fracture is primarily due to non-ideal grain interactions with slight dependence on high-rate charge demands. Essentially, when neighboring grains were misaligned, they expanded different rates relative to one another leading to high stresses and ultimately the formation of intraparticle cracks. The model predicted that small particles with large grains develop significantly less damage than larger particles with small grains. Finally, the model predicted most of the chemo-mechanical damage accumulates in the first charge after formation. This chemo-mechanical "damage saturation" effect indicated that initial particle fracture occurs within the first few cycles, while long-term cathode degradation is not solely chemo-mechanically induced. This led to a need for simulating fatigue-like mechanism that degrade the battery over longer time scales. In order to reach the time scales, need to resolve fatigue-like degradation, the CDM needs to be complemented by a faster model. Therefore, recent efforts have been focused on using results from the CDM to inform parameters within the SPM. These parameters are homogenization factors that are associated with diffusion, particle radius, and/or exchange current density. By coupling the CDM to the SPM, the aging simulation is broken up into two domains: short-term and long-term degradation. The short-term degradation occurs over a single cycle and is handled by the CDM due of its high fidelity, but relatively expensive computational cost. Such mechanism include break-in crack caused by mismatches in grain orientation. The long-term degradation occurs over tens of cycles and is handled by the SPM due it's computational efficiency. Most of the fatigue-like mechanism fall into this category. The eventual goal of this modeling framework is to upscale to a psudo-2D model allowing for full electrode simulation, which are informed by high-fidelity grain-scale simulations.

electrochemistry↗
DOE OSTI2024

Effects of Coatings on Water Intrusion and Strain Gauge Durability in Submerged Fatigue Conditions: Preprint

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand the combined effects of moisture intrusion and mechanical fatigue on marine energy structures, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Measuring strain is critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions was not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure, strains, and strain gauge failure modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite fatigue testing↗
DOE OSTI2024

Effects of Strain Gauge Coatings on Water Intrusion in Submerged Composite Coupon Testing

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗
DOE OSTI2021

FAST.Farm load validation for single wake situations at alpha ventus

The main objective of the presented work is the validation of the simulation tool FAST.Farm for the calculation of power and structural loads in single wake situations; the basis for the validation is the measurement database of the operating offshore wind farm alpha ventus. The approach is described in detail and covers the calibration of the aeroelastic turbine model, transfer of environmental conditions to simulations, and comparison between simulations and adequately filtered measurements. It is shown that FAST.Farm accurately predicts power and structural load distributions over wind direction with discrepancies of less than 10 % for most of the cases compared to the measurements. Additionally, the frequency response of the structure is investigated, and it is calculated by FAST.Farm in good agreement with the measurements. In general, the calculation of fatigue loads is improved with a wake-added turbulence model added to FAST.Farm in the course of this study.

17 WIND ENERGY↗
DOE OSTI2026

Time-Domain Vortex Induced Vibration Modeling of Reference Dynamic Power Cable for the Gulf of Maine

Vortex-induced vibration (VIV) is a phenomenon known to decrease the fatigue life of dynamic power cables used in floating offshore wind systems through increased bending loading cycles. A variety of modeling solutions have been proposed to study this, but none enable fully-coupled simulations leveraging open-source tools. To address this, a time-domain VIV model has been successfully implemented into the open-source mooring dynamics model MoorDyn. The semi-empirical VIV model describes a lift force acting on segments of a flexible cylinder, making it well suited for implementation into MoorDyn. The new capability successfully predicted the frequencies and magnitudes of strain in both steady and oscillating flows when compared to the original validation results and matched peak spectral response when compared to experimental results, verifying successful implementation. MoorDyn with VIV was then leveraged to simulate a 15 MW floating turbine with a dynamic power cable in the Gulf of Maine using OpenFAST for six return periods of combined wind, wave, and current conditions. Increased curvature and tension fluctuations in higher flow speeds were observed when simulating VIV. Maximum tensions and curvatures also increased, with the 500 year conditions violating the curvature factor of safety of 2.0. These results highlight the importance of considering VIV when designing dynamic power cables for the Gulf of Maine, and indicate that cost effective mitigation strategies should be explored for the area. They also demonstrate the utility of this new modeling capability, which provides the first open-source tool for fully coupled time-domain floating offshore wind simulations with dynamic power cable VIV.

17 WIND ENERGY↗
DOE OSTI2022

An extrapolation method for strain ranges and hold times in developing the EPP+SMT creep-fatigue design curves for Alloy 617

Experimental and numerical studies in developing the integrated Elastic–Perfectly Plastic (EPP) plus Simplified Model Test (SMT) design methodology, referred to as the EPP+SMT method, continued in FY2022. This report focuses on the methods for extrapolating the EPP+SMT creep-fatigue (CF) design curves at long hold times and low strain ranges. In this study, the available CF failure data on Alloy 617 at 950°C were analyzed to determine a set of CF failure criteria. At very low strain ranges and long hold times, CF failure data are not accessible by experiments because of the extraordinarily long test durations and the inability of the test machines to accurately control these small strain ranges. A CF experimental approach with the concept of block-strain range CF testing protocol was developed. Tests using this protocol were conducted to generate the needed information for calibrating material parameters of the numerical material models. The Time Fraction based method and Dissipated Energy method were used to extrapolate the CF life curves to low strain ranges and long hold times. Based on the new experimental approach and CF life prediction methods, the CF life curves with various hold times were developed for Alloy 617 at 950°C. In addition, an experiment was designed and is being performed to verify the predicted CF curves at 950°C. The extrapolation procedure will be applied at lower temperatures to complete the development of the EPP+SMT CF design curves for Alloy 617 in F2023.

36 MATERIALS SCIENCE↗
DOE OSTI2023

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Uncertainty Quantification of Monolithic Tungsten Target Block Fatigue

The current STS spallation target design consists of 21 water cooled, tantalum clad, monolithic tungsten blocks. The target wheel assembly rotates such that each target block receives a direct proton pulse every 1.4 seconds (21 blocks / 15 Hz pulses). The quasi-steady heating induced by the repetitive beam pulses creates a significant mean stress distribution in the target. On top of this, the rapid energy deposition from a proton pulse induces dynamic stress waves that are of the same order of magnitude as the mean stresses. Over the design goal of 5,000 operational hours per year for a decade, each target must withstand over 130 million repetitions of these dynamic stress events. The fatigue life prediction of the target blocks is a complex sequence of simulations that depend upon a set of input parameters. For the tungsten block, the end goal is the fatigue factor-of-safety (FOS). This study documents a new structural analysis routine using software available to U.S. national laboratories (e.g. CUBIT, Sierra Multiphysics, Dakota) that enables more rapid target fatigue analysis. The increased throughput is amenable to parameter sensitivity and uncertainty quantification (UQ) studies. A set of input parameters (ultimate strength, fatigue strength, density, elastic modulus, Poisson’s ratio, thermal conductivity, coefficient of thermal expansion, specific heat, flow rate) with expected ranges are documented based on literature data, recent experimental testing, and engineering judgement. UQ bounds the resulting fatigue FOS at [0.5, 3.4] using epistemic interval analysis. These bounds are expected to be wider due to model effects (discretization) and beam effects (focus, offset) that were not included. Parameter sensitivity underscores the importance of ultimate strength and fatigue strength of irradiated tungsten on the fatigue calculations.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Design by analysis rules for ASME Section III, Division 5, Class B components

The current rules for elevated temperature ASME Section III, Division 5, Class B components, other than piping, were basically adapted from the Design-by-Rule approach for Section VIII, Division 1 vessels. A goal of the proposed new rules is to explicitly account for the design life and cyclic service while recognizing the less-rigorous requirements commensurate with lesser safety consideration. Further goals are to maximize the use of modern computational technology, for example finite element analysis in conjunction with reference stress concepts, and to avoid the need for stress classification. This paper summarizes the work done to address these issues. A summary of the design-by-analysis for primary loads, strain limit evaluation, and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules and the experimental data obtained from a family of a simplified model test-based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development of a Machine-Learned Cruise Guide Indicator for Rotorcraft

This paper presents a machine-learned virtual cruise guide indicator (vCGI) for Chinook helicopters. Two temporal neural networks were trained and evaluated on measured data from 55 flight tests, one for the fore rotor and another for the aft rotor, to predict a vCGI value, which protects 23 components from fatigue damage during steady-state conditions. Three different classes of machine learning architectures were evaluated for prediction of the vCGI from time sequences: a temporal convolutional neural network with 1D dilated causal convolutions, a long short-term memory recurrent neural network, and an attention-based transformer architecture. The final average model accuracy on unseen flight data is currently greater than 93% for CGI values which could result in fatigue damage and 90% for normal operation CGI values. Model accuracy was improved through a series of advancements in:(1) selection of optimal training data using temporal collective variables and unsupervised learning, (2) dataset augmentation with maximum-entropy temporal collective variables, and (3) implementation of a mixture-of-experts classification- regression approach using an adversarial classification approach to assign maneuver labels. The results are presented for each advancement in model development along with lessons learned in training machine learning models on real- world, time-dependent rotorcraft data.

Boyer, Mathew↗
DOE OSTI2024

A comparative analysis of residual stresses from friction stir processing of aluminum cast 380 and wrought 7075 alloy sheets: experimental characterization and modeling

Residual stresses are often overlooked in friction stir processing (FSP), but their significant impact on fatigue performance necessitates their consideration in optimizing processing parameters. The first step in this effort is understanding how process conditions influence residual stress distributions, especially across different alloys. This study focuses on determining and explaining the through-thickness residual stress variations and the effect of process temperature on the residual stress magnitude in wrought AA7075 and cast AA380.0 alloys. Additionally, for AA380.0, the impact of a second FSP pass was investigated. To achieve this, hole-drilling electronic speckle pattern interferometry (ESPI) and the thermal pseudo-mechanical (TPM) model within finite element analysis were employed to study the 3D distributions of in-plane residual stresses in processed samples under various conditions. A key finding was the varying impact of process temperatures on residual stress magnitudes. Higher process temperatures reduced stresses in AA380.0 but increased them in AA7075. Additionally, the through-thickness stress distributions differed between the two alloys. Further analysis revealed that yield stresses are crucial in explaining these phenomena and the effects of additional FSP passes. Further, this fundamental understanding will be vital in guiding the efforts to mitigate residual stresses and assess their impact on the performance of FSP aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Report on FY 2020 Testing in Support of the Development and Extension of ASME Code Rules for Grade 91

This report summarizes the FY 2020 research and activities at Oak Ridge National Laboratory in support of the ASME code rule development and code extension for Grade 91 (Gr. 91) steel. Incorporation of the Gr. 91 temperature-dependent fatigue curves in Section III Division 5 was one major task, and the associated major aspects brought up during the course of the ASME balloting process are documented in this report. Experiments and analysis continued on the development of the alternative creep-fatigue evaluation based on elastic–perfectly plastic (EPP) plus simplified model test (SMT) methodology. The focus of the study in FY 2020 was the evaluation of the hold-time effect at high cycle and low strain range region. Baseline testing in support of the evaluation of hold time effects was started and will continue in FY 2021. Major on-going experiments and activities in support of the ASME code development and extension of Gr. 91 will be completed in FY 2021.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗