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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Hurricane Resilient Wind Plant Concept Study Final Report

Hurricanes occur over much of the U.S. Atlantic and Gulf coasts, from Long Island to the U.S.-Mexico border, encompassing much of the nation's primary offshore wind resource. Category 5 hurricanes have made landfall as far north as North Carolina, with Category 3 hurricanes reaching New York with some frequency. Along the US West coast, typhoons strike with similar frequency and severity. At present, offshore wind turbine design practices do not fully consider the severe operating conditions imposed by hurricanes. Although universally applied to most turbine designs, International Electrotechnical Commission (IEC) standards do not sufficiently address the duration, directionality, magnitude, or character of hurricanes. To assess advanced design features that could mitigate hurricane loading in various ways, this Hurricane-Resilient Wind Plant Concept Study considered a concept design study of a 500-megawatt (MW) wind power plant consisting of 10-MW wind turbines deployed in 25-meter (m) water depths in the Western Gulf of Mexico. This location was selected because hurricane frequency and severity provided a unique set of design challenges that would enable assessment of hurricane risk and projection of cost of energy (COE) changes, all in response to specific U.S. Department of Energy (DOE) objectives. Notably, the concept study pursued a holistic approach that incorporated multiple advanced system elements at the wind turbine and wind power plant levels to meet objectives for system performance and reduced COE. Principal turbine system elements included a 10-MW rotor with structurally efficient, low-solidity blades; a lightweight, permanent-magnet, direct-drive generator, and an innovative fixed substructure. At the wind power plant level, turbines were arrayed in a large-scale wind power plant in a manner aimed at balancing energy production against capital, installation, and operation and maintenance (O&M) costs to achieve significant overall reductions in COE.

17 WIND ENERGY↗
DOE OSTI2017

Lightweight Hexagonal Boron Nitride Foam for CO 2 Absorption

Weak van der Waals forces between inert hexagonal boron nitride (h-BN) nanosheets make it easy for them to slide over each other, resulting in an unstable structure in macroscopic dimensions. Creating interconnections between these inert nanosheets can remarkably enhance their mechanical properties. However, controlled design of such interconnections remains a fundamental problem for many applications of h-BN foams. In this work, a scalable in situ freeze-drying synthesis of low-density, lightweight 3D macroscopic structures made of h-BN nanosheets chemically connected by poly(vinyl alcohol) (PVA) molecules via chemical cross-link is demonstrated. Unlike pristine h-BN foam which disintegrates upon handling after freeze-drying, h-BN/PVA foams exhibit stable mechanical integrity in addition to high porosity and large surface area. Fully atomistic simulations are used to understand the interactions between h-BN nanosheets and PVA molecules. In addition, the h-BN/PVA foam is investigated as a possible CO 2 absorption and as laser irradiation protection material.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

The Hot Bending and Diffusion Bonding of TiAl-Based Alloy for Corrugated-Core Sandwich Structure

The multi-layer structure of TiAl-based alloys can meet the demand of having lightweight and high-strength properties at elevated temperature. In this paper, the corrugated-core sandwich structure of a TiAl-based alloy was fabricated by the hot bending/diffusion bonding process. In order to fabricate this structure, the high-temperature tensile property, hot bending behavior, and vacuum diffusion bonding of a Ti-47.5Al-Cr-V alloy were investigated. The flow behavior was evaluated by uniaxial tensile experiment, and the results showed that the alloy exhibited good plasticity at the given conditions, and the maximum elongation reached 200% at 1000 °C at strain rate of 3 × 10{sup −4} s{sup −1}. The bending experiments were also performed at temperatures of 950, 1000, and 1050 °C with fillet radii of R = 0, 0.5, and 1 mm, respectively. No micro-/macro-defects developed. The vacuum diffusion bonding of this alloy was also carried out, and the shear bonding strength of bonding joints was measured at room temperature. The maximum shear strength was 398 MPa, and the joint was obtained at 1000 °C/30 MPa/3 h. Combining the bonding interface with the shear strength of different joints, the appropriate bonding pressure and bonding time for diffusion bonding of the TiAl alloy at 1000 °C were 20 MPa and 2 h, respectively. Then, the forming process of the corrugated-core sheet was conducted at 1000 °C with a fillet radius of 1 mm. Finally, the corrugated-core sandwich structure was manufactured under vacuum atmosphere, and the mechanical properties and the interface microstructure were investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Three-dimensional skeleton networks of graphene wrapped polyaniline nanofibers: An excellent structure for high-performance flexible solid-state supercapacitors

Thin, robust, lightweight, and flexible supercapacitors (SCs) have aroused growing attentions nowadays due to the rapid development of flexible electronics. Graphene-polyaniline (PANI) hybrids are attractive candidates for high performance SCs. In order to utilize them in real devices, it is necessary to improve the capacitance and the structure stability of PANI. Here we report a hierarchical three-dimensional structure, in which all of PANI nanofibers (NFs) are tightly wrapped inside reduced graphene oxide (rGO) nanosheet skeletons, for high-performance flexible SCs. The as-fabricated film electrodes with this unique structure showed a highest gravimetric specific capacitance of 921 F/g and volumetric capacitance of 391 F/cm 3 . The assembled solid-state SCs gave a high specific capacitance of 211 F/g (1 A/g), a high area capacitance of 0.9 F/cm 2 , and a competitive volumetric capacitance of 25.6 F/cm 3 . The SCs also exhibited outstanding rate capability (~75% retention at 20 A/g) as well as excellent cycling stability (100% retention at 10 A/g for 2000 cycles). Additionally, no structural failure and loss of performance were observed under the bending state. Lastly, this structure design paves a new avenue for engineering rGO/PANI or other similar hybrids for high performance flexible energy storage devices.

36 MATERIALS SCIENCE↗
DOE OSTI2024

OpenFAST Modeling of the T-Omega Wind Floating Offshore Wind Turbine System

To reduce the cost of offshore wind energy through a more efficient design of the floating support structure, T-Omega Wind developed a novel lightweight and shallow-draft platform concept that aims to achieve a wave-following behavior without resonance amplification. The rotor and generator are carried by four tower legs with each leg supported by a shallow-draft float at the base. In preparation for a more detailed analysis, a coupled aero-hydro-elastic model of the proposed concept is developed in OpenFAST. The detailed modeling approach is presented, including a novel application of the SubDyn substructure dynamics module of OpenFAST to approximate the loads on the axle tube at the tower top from the rotor hub bearings. Preliminary results obtained with the OpenFAST model by rigidifying the substructure and blades indicate that the original sizing of the design can lead to large hub acceleration in the axial/surge and pitch directions due to platform-pitch motion. The high axial acceleration also potentially leads to large bending moments in the four tower legs. To address these issues, an updated design is developed with, among other changes, increased float spacing at the tower base and improved shear-transmitting geometry of the tower legs. The new design suggests significantly reduced extreme hub accelerations under the same conditions even with structural flexibility and will be further analyzed in the future through full aero-hydro-servo-elastic simulations.

FOWT↗
DOE OSTI2024

OpenFAST Modeling of the T-Omega Wind Floating Offshore Wind Turbine System

To reduce the cost of offshore wind energy through a more efficient design of the floating support structure, T-Omega Wind developed a novel lightweight and shallow-draft platform concept that aims to achieve a wave-following behavior without resonance amplification. The rotor and generator are carried by four tower legs with each leg supported by a shallow-draft float at the base. In preparation for a more detailed analysis, a coupled aero-hydro-elastic model of the proposed concept is developed in OpenFAST. The detailed modeling approach is presented, including a novel application of the SubDyn substructure dynamics module of OpenFAST to approximate the loads on the axle tube at the tower top from the rotor hub bearings. Preliminary results obtained with the OpenFAST model by rigidifying the substructure and blades indicate that the original sizing of the design can lead to large hub acceleration in the axial/surge and pitch directions due to platform-pitch motion. The high axial acceleration also potentially leads to large bending moments in the four tower legs. To address these issues, an updated design is developed with, among other changes, increased float spacing at the tower base and improved shear-transmitting geometry of the tower legs. The new design suggests significantly reduced extreme hub accelerations under the same conditions even with structural flexibility and will be further analyzed in the future through full aero-hydro-servo-elastic simulations.

ENGINEERING,WIND ENERGY↗
DOE OSTI2022

Multiscale mechanical design of the lightweight, stiff, and damage-tolerant cuttlebone: A computational study

Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy absorption capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here, in this work, we computationally investigate how such remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 38 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy absorption while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Ultralight Door Design, Development and Demonstration Project (Final Scientific Report)

The project objectives associated with the Ultralight Door Project were to develop a lightweight driver's side door, 42.5% lighter than a current model year high-volume baseline door, at an incremental cost not to exceed $ \$ $ 5 per pound saved, while maintaining equivalent functionality, safety, corrosion, durability and sound transmission performance of the baseline vehicle. The project approach included the selection of a door architecture, development of a key performance target matrix and incremental cost model. Several unique door structures were developed and evaluated using computer-aided engineering (CAE) and cost modeling tools. The aluminum-intensive door structure was the only design capable of meeting both the performance and cost criteria objectives. The door module, glass, interior trim, latch and electrical subsystems were functionally integrated with the aluminum door structure, enabling additional mass reduction beyond material substitution. The lightweight door design was prototyped, integrated with baseline vehicles and tested to validate equivalent functionality and performance. The project results demonstrate a mass reduction of 15.2 kg (40%) at an incremental cost of $ \$ $2.81 per pound saved, while maintaining functionality and performance of the baseline door. The environmental benefit associated with the Ultralight Door enables a 6g CO 2 eq. per kilometer environmental benefit, for a 4-door vehicle powered by a downsized fuel injected gasoline combustion engine. The project results were presented and published in the 2018 SAE International Conference proceedings and in the Journal of Life Cycle Assessment.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Materials (FY 2022 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2022. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Origami‐Based Reconfigurable Metamaterials for Tunable Chirality

Origami is the art of folding two‐dimensional (2D) materials, such as a flat sheet of paper, into complex and elaborate three‐dimensional (3D) objects. This study reports origami‐based metamaterials whose electromagnetic responses are dynamically controllable via switching the folding state of Miura‐ori split‐ring resonators. The deformation of the Miura‐ori unit along the third dimension induces net electric and magnetic dipoles of split‐ring resonators parallel or anti‐parallel to each other, leading to the strong chiral responses. Circular dichroism as high as 0.6 is experimentally observed while the chirality switching is realized by controlling the deformation direction and kinematics. In addition, the relative density of the origami metamaterials can be dramatically reduced to only 2% of that of the unfolded structure. These results open a new avenue toward lightweight, reconfigurable, and deployable metadevices with simultaneously customized electromagnetic and mechanical properties.

Wang, Zuojia↗
DOE OSTI2022

Construction of Fluorine- and Piperazine-Engineered Covalent Triazine Frameworks Towards Enhanced Dual-Ion Positive Electrode Performance

Organic positive electrodes featuring lightweight, and tunable energy storage modes by molecular structure engineering have promising application prospects in dual-ion batteries. Herein, a series of highly porous covalent triazine frameworks (CTFs) were synthesized under ionothermal conditions using fluorinated aromatic nitrile monomers containing a piperazine ring. Fluorinated monomers can result in more defects in CTFs, leading to a higher surface area up to 2515 m 2 /g and a higher N content of 11.34 wt% compared to the products from the non-fluorinated monomer. The high surface area and abundant redox sites of these CTFs afforded high specific capacities (up to 279 mAh/g at 0.1 A/g), excellent rate performance (89 mAh/g at 5 A/g), and durable cycling performance (92.3% retention rate after 500 cycles at 2.0 A g -1 ) as dual-ion positive electrodes

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Tensile and fatigue characterization of multifunctional composites

This research is part of a larger effort to develop advanced self-sensing multifunctional polymer composites that are both lightweight and high-strength, while also enabling structural damage detection, fatigue cycle monitoring, and service life prediction. These multifunctional composites are particularly sought after in the automotive industry for their potential to significantly reduce vehicle weight and simultaneously provide additional functionality like condition monitoring to enhance safety. This study examines the tensile and fatigue properties of a composite material composed of acrylonitrile butadiene styrene (ABS) polymer embedded with piezoelectric barium titanate (BaTiO3) nanoparticles. The integration of BaTiO3 nanoparticles not only supplies the material with self-sensing capabilities but also influences its mechanical properties. While a high content of BaTiO3 nanoparticles is desired to enhance sensing capacity, the brittle nature of such materials causes concerns of decreased strength characteristics. To explore this, various composite samples were fabricated with nanoparticle contents ranging from 0 wt% to 20 wt%. These samples underwent tensile testing to measure their ultimate tensile strengths and Young’s moduli. Following this, fatigue tests were conducted to generate S-N curves, which are essential for understanding the material's durability under cyclic loading. The findings from these tests assess the impact of nanoparticle content on the composite’s tensile strength and fatigue life, providing essential insights that can guide the optimization and design of future self-sensing multifunctional composites. The results suggest that 5 wt% BaTiO3 provides an optimal balance between mechanical properties and nanoparticle concentration, making it a promising composition for semi-structural applications.

Bowland, Christopher [ORNL] (ORCID:000000021229431↗
DOE OSTI2016

Carbon Fiber from Biomass

Carbon fiber (CF), known also as graphite fiber, is a lightweight, strong, and flexible material used in both structural (load-bearing) and non-structural applications (e.g., thermal insulation). The high cost of precursors (the starting material used to make CF, which comes predominately from fossil sources) and manufacturing have kept CF a niche market with applications limited mostly to high-performance structural materials (e.g., aerospace). Alternative precursors to reduce CF cost and dependence on fossil sources have been investigated over the years, including biomass-derived precursors such as rayon, lignin, glycerol, and lignocellulosic sugars. The purpose of this study is to provide a comprehensive overview of CF precursors from biomass and their market potential. We examine the potential CF production from these precursors, the state of technology and applications, and the production cost (when data are available). We discuss their advantages and limitations. We also discuss the physical properties of biomass-based CF, and we compare them to those of polyacrylonitrile (PAN)-based CF. We also discuss manufacturing and end-product considerations for bio-based CF, as well as considerations for plant siting and biomass feedstock logistics, feedstock competition, and risk mitigation strategies. The main contribution of this study is that it provides detailed technical and market information about each bio-based CF precursor in one document while other studies focus on one precursor at a time or a particular topic (e.g., processing). Thus, this publication allows for a comprehensive view of the CF potential from all biomass sources and serves as a reference for both novice and experienced professionals interested in CF production from alternative sources.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

OpenFAST Modeling of the T-Omega Wind Floating Offshore Wind Turbine System: Preprint

To reduce the cost of offshore wind energy through a more efficient design of the floating support structure, T-Omega Wind developed a novel lightweight and shallow-draft platform concept that aims to achieve a wave-following behavior without resonance amplification. The rotor and generator are carried by four tower legs with each leg supported by a shallow-draft float at the base. In preparation for a more detailed analysis, a coupled aero-hydro-elastic model of the proposed concept is developed in OpenFAST. The detailed modeling approach is presented, including a novel application of the SubDyn substructure dynamics module of OpenFAST to approximate the loads on the axle tube at the tower top from the rotor hub bearings. Preliminary results obtained with the OpenFAST model by rigidifying the substructure and blades indicate that the original sizing of the design can lead to large hub acceleration in the axial/surge direction and in the pitch direction due to platform-pitch motion. The high hub acceleration also potentially leads to large bending moments in the four tower legs. To address the issue identified, an updated design is developed with, among other changes, increased float spacing at the tower base and improved geometry of the tower legs. The new design suggests significantly reduced extreme platform pitch angles under the same conditions and will be further analyzed in the future through full aero-hydro-servo-elastic simulations.

FOWT↗
DOE OSTI2015

SURFACE MORPHOLOGY OF CARBON FIBER POLYMER COMPOSITES AFTER LASER STRUCTURING

The increasing use of Carbon Fiber Polymer Composite (CFPC) as a lightweight material in automotive and aerospace industries requires the control of surface morphology. In this study, the composites surface was prepared by ablating the resin in the top fiber layer of the composite using an Nd:YAG laser. The CFPC specimens with T700S carbon fiber and Prepreg - T83 resin (epoxy) were supplied by Plasan Carbon Composites, Inc. as 4 ply thick, 0/90o plaques. The effect of laser fluence, scanning speed, and wavelength was investigated to remove resin without an excessive damage of the fibers. In addition, resin ablation due to the power variation created by a laser interference technique is presented. Optical property measurements, optical micrographs, 3D imaging, and high-resolution optical profiler images were used to study the effect of the laser processing on the surface morphology.

Sabau, Adrian S↗
DOE OSTI2017

PRESAGE: Protecting Structured Address Generation against Soft Errors

Modern computer scaling trends in pursuit of larger component counts and power efficiency have, unfortunately, lead to less reliable hardware and consequently soft errors escaping into application data ("silent data corruptions"). Techniques to enhance system resilience hinge on the availability of efficient error detectors that have high detection rates, low false positive rates, and lower computational overhead. Unfortunately, efficient detectors to detect faults during address generation (to index large arrays) have not been widely researched. We present a novel lightweight compiler-driven technique called PRESAGE for detecting bit-flips affecting structured address computations. A key insight underlying PRESAGE is that any address computation scheme that flows an already incurred error is better than a scheme that corrupts one particular array access but otherwise (falsely) appears to compute perfectly. Enabling the flow of errors allows one to situate detectors at loop exit points, and helps turn silent corruptions into easily detectable error situations. Our experiments using PolyBench benchmark suite indicate that PRESAGE-based error detectors have a high error-detection rate while incurring low overheads.

Sharma, Vishal C.↗
DOE OSTI2019

Buckling of Two-Dimensional Covalent Organic Frameworks under Thermal Stress

Two-dimensional covalent organic frameworks (2D COFs) are periodic, permanently porous, and lightweight solids that are polymerized from topologically designed monomers. The predictable design and structural modularity of these materials make them promising candidates for applications including catalysis, environmental remediation, chemical separations, and organic electronics, many of which will require stability to mechanical and thermal stress. Based on their reinforced structures and high degradation temperatures, as determined by thermal gravimetric analysis (TGA), many reports have claimed that COFs have excellent thermal stability. However, their stability to heat and pressure has not been probed using methods that report on structural changes rather than the loss of volatile compounds. Here, we explore two structurally analogous 2D COFs with different polymerization chemistries using in operando X-ray diffraction (XRD), which demonstrates the loss of crystallinity at lower temperatures than the degradation temperatures measured by TGA. Density functional theory calculations suggest that an asymmetric buckling of the COF lattice is responsible for the observed loss of crystallinity. In addition to their thermal stability, XRD of the 2D COFs under gas pressures up to 100 bar showed no loss in crystallinity or structural changes, indicating that these materials are robust to mechanical stress by applied pressure. We expect that these results will encourage further exploration of COF stability as a function of framework design and isolated form, which will guide the design of frameworks that withstand demanding application-relevant conditions.

Evans, Austin↗