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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Multi-fidelity information fusion and resource allocation

This project created and demonstrated a framework for the efficient and accurate prediction of complex systems with only a limited amount of highly trusted data. These next generation computational multi-fidelity tools fuse multiple information sources of varying cost and accuracy to reduce the computational and experimental resources needed for designing and assessing complex multi-physics/scale/component systems. These tools have already been used to substantially improve the computational efficiency of simulation aided modeling activities from assessing thermal battery performance to predicting material deformation. This report summarizes the work carried out during a two year LDRD project. Specifically we present our technical accomplishments; project outputs such as publications, presentations and professional leadership activities; and the project’s legacy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Collaborative Research: Improved Efficiency and Coupling of the Radiation Code in the ACME Earth System Model (Final Report)

The complexity of radiative transfer, its importance to the exchange of energy in the climate system, and its high computational cost establishes importance of an accurate and efficient radiative transfer parameterization for climate simulation. Previous work by the proposing team at AER led to the development of the radiation code, RRTMG, which has been widely accepted by the global modeling community as a fast and accurate advancement over the previous generation of radiation codes. It has been in use in the NCAR CESM for many years, and it has been implemented in the initial version the DOE E3SM model. However, its computational cost remains high relative to other components in part due to its complexity and to its inefficient use of modern optimization strategies, and this project helped address this limitation for the code’s application in E3SM. Under other funding, the Investigators of this project led an effort to develop a high-performance broadband radiation code, called RTE+RRTMGP, which is a completely restructured code that will take advantage of modern computational capabilities to enhance its performance while retaining the strengths and accuracy of the original code. Designed to perform over a range of computer architectures, RTE+RRTMGP makes extensive use of Fortran 2003 features to improve both its efficiency and its use of memory. RTE+RRTMGP is expected to be adopted in the next generation of RTE+RRTMGP. This project allowed for advancements to the code’s computational capabilities and adding new and enhanced features. This included revising RTE+RRTMGP to run on GPU processors, analysis of and improvements to the code’s timing, modifying the gas optics in RRTMGP to increase the code’s accuracy, extensive validation of computed fluxes, heating rates and forcings, generating a cloud optical property and vertical sampling capabilities for RTE+RRTMGP, implementing a fast and accurate longwave scattering capability, and groundwork for the inclusion of a capability to specify solar variability. Many of the accomplishment in this project necessitated significant collaboration with the E3SM development team. The result of this project was optimization of a key physical component (radiative transfer calculations) of E3SM, directly supporting E3SM’s overarching global modeling objectives. More broadly, this project provided overall advancements in the use of radiative transfer calculations in atmospheric modeling and simulation, particularly for climate.

58 GEOSCIENCES↗
NASA NTRS2012

The Impact of Early Design Phase Risk Identification Biases on Space System Project Performance

Risk identification during the early design phases of complex systems is commonly implemented but often fails to result in the identification of events and circumstances that truly challenge project performance. Inefficiencies in cost and schedule estimation are usually held accountable for cost and schedule overruns, but the true root cause is often the realization of programmatic risks. A deeper understanding of frequent risk identification trends and biases pervasive during space system design and development is needed, for it would lead to improved execution of existing identification processes and methods.

Reeves, John D., Jr.↗
NASA NTRS2016

Photonic Integrated Circuit (PIC) Device Structures: Background, Fabrication Ecosystem, Relevance to Space Systems Applications, and Discussion of Related Radiation Effects

Electronic integrated circuits are considered one of the most significant technological advances of the 20th century, with demonstrated impact in their ability to incorporate successively higher numbers transistors and construct electronic devices onto a single CMOS chip. Photonic integrated circuits (PICs) exist as the optical analog to integrated circuits; however, in place of transistors, PICs consist of numerous scaled optical components, including such "building-block" structures as waveguides, MMIs, lasers, and optical ring resonators. The ability to construct electronic and photonic components on a single microsystems platform offers transformative potential for the development of technologies in fields including communications, biomedical device development, autonomous navigation, and chemical and atmospheric sensing. Developing on-chip systems that provide new avenues for integration and replacement of bulk optical and electro-optic components also reduces size, weight, power and cost (SWaP-C) limitations, which are important in the selection of instrumentation for specific flight projects. The number of applications currently emerging for complex photonics systems-particularly in data communications-warrants additional investigations when considering reliability for space systems development. This Body of Knowledge document seeks to provide an overview of existing integrated photonics architectures; the current state of design, development, and fabrication ecosystems in the United States and Europe; and potential space applications, with emphasis given to associated radiation effects and reliability.

Body of Knowledge (BOK)↗
DOE OSTI2022

Assessing the New Home Market Opportunity: Case Study and Cost Modeling for Solar and Storage in 2030

Residential solar and storage markets are growing in the United States. With approximately 1 million new homes constructed every year, this represents a significant opportunity for solar and storage installations. Some homebuilders have begun to build new homes with solar and storage included as a standard offering. It is not clear how solar and storage is incorporated into the new construction process and at what cost. Further, it is unclear what barriers or opportunities exist to scale this model nationwide. To fill this gap in the literature, this research conducts a case study of Mandalay Homes' new solar and storage community in Arizona to gather lessons learned. From this foundation, we further generate a set of pathways to reduce install costs and expand solar and storage market penetration in this sector. To model existing and 2030 solar and storage costs, we use the National Renewable Energy Laboratory's (NREL's) bottom-up cost model. This modeling is further informed by 12 interviews conducted with new home builders, solar contractors, and other subject matter expert organizations. Our case study analysis generated three key considerations for other homebuilders including: 1. Educating local permitting, inspection, and in some cases utility officials on solar and storage products, designs, and code compliant building practices may be required. The need for education may decline as more local governments and utilities review and approve solar and storage projects. 2. Incorporating solar and storage systems into the homebuilding process can add complexity and related coordination challenges. This does not need to result in home construction delays, but can result in costly contractor "dry runs" to construction sites. 3. Deploying solar and storage at the time of new construction has significant economies of scale, which can improve the value proposition of the systems. The case study, extant literature, and interviews were used to model both existing and future solar and storage installation costs at time of new construction. Here, we find three key cost reduction opportunities relating to solar and battery storage hardware, customer acquisition, and overhead. If future contractors can maximize the cost reduction opportunities outlined here, residential new construction costs could decline by 8 - 25% by 2030, depending on the modeled scenario. Though we expect costs to decline through 2030, it is unclear which of these scenarios may ultimately appear. Interviewees further identified a variety of barriers across each cost category that could temper the savings shown here. At the same time, interviewees described several pathways to scale the new construction solar and storage market, beyond installation cost savings. Interviewees confirmed that changes in finance, rate design, resilience policies, deployment mandates, and DER aggregation could all support more market adoption than seen today. These findings suggest that there are significant opportunities to expand new construction markets and this research can serve as a baseline to assess progress in this segment through 2030.

14 SOLAR ENERGY↗
DOE OSTI2026

An AI-driven framework for evaluating local and state authorities’ permitting processes

The demand for new energy infrastructure is increasing across the United States, but heterogenous permitting processes and embedded requirements across different local jurisdictions can cause project delays, increase “soft costs,” and hinder developer expansion. This study analyzes the variability in local permitting requirements across the U.S. and develops a quantitative approach to describe their clarity and effectiveness in enabling infrastructure project development. By using an Energy Language Model (ELM), a large language model (LLM) for energy technologies, we systematically gathered permitting information from nearly 300 state-, county-, and city-level documents, creating a structured dataset of requirements and procedures on an unprecedented scale and speed. Our analysis revealed that local (city and county) permitting requirement documents are underrepresented compared to state-level guidance documents, which can impede timely and cost-effective installation of new electric infrastructure. Our validation process showed that the final database has an accuracy of approximately 95%. We, further, created a new quantitative method to score permitting requirements for clarity and efficiency, with electric vehicle supply equipment as an initial use case. The average local permitting document scored a 1.8 out of 5, which we interpret as meaning that half of the requirements developers face when installing electric infrastructure are ambiguous, increasing both cost and time. We also created a “Generalized Permit Process”, highlighting common procedural steps and identifying specific opportunities for municipalities to improve their documentation. This research establishes a systematic and scalable framework for evaluating the complexities of local infrastructure permitting processes by combining LLM-powered data collection and quantitative scoring. The framework enables policymakers and developers to identify and mitigate procedural bottlenecks, with the expectation that these improvements can accelerate application review and approval, reduce project costs, and expedite connection to utility distribution grids. As a foundational approach for streamlining local project development processes, this study’s methods are intended to be extended to a wide range of energy applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Batteries Included: Top 10 Findings from Berkeley Lab Research on the Growth of Hybrid Power Plants in the United States

One of the most important electric power system trends of the 2010s was the rapid deployment of wind turbines and photovoltaic arrays, but a twist for the 2020s may be the rapid deployment of ‘hybrid’ generation resources. Hybrid power plants typically combine solar or wind (or other energy sources) with co-located storage. While hybridization helps to ease the challenge of balancing variable supply and demand, its relative novelty means that research is needed to facilitate integration and promote innovation. Combining the characteristics of multiple energy, storage, and conversion technologies poses complex questions for grid operations and economics. Project developers, system operators, planners, and regulators would benefit from better data, methods, and tools to estimate the costs, values, and system impacts of hybrid projects. This publication showcases some of Berkeley Lab’s robust research program intended to support private- and public-sector decision-making about hybrid plants in the United States. Our short briefing summarizes articles that we published between 2020 and 2022, links to the in-depth reports, and provides contact details for further engagement on the specific research topics: Growth: Developer interest in hybrid power plants is strong and growing Price vs. Value: PV+storage hybrids have low PPA prices and high value in some regions Market Drivers: Solar hybridization is driven by tax credits and other benefits Configuration Choices: Market prices have incentivized shorter duration batteries with PV Capacity Value: The capacity contribution of a hybrid is less than the sum of its parts Ancillary Services: AS markets are a valuable yet fleeting option for hybrids Market Participation: Hybrids can more flexibly engage with electricity markets Operations: The power system value of hybrids depends on how they are operated Distributed Hybrids: Growth of customer-sited PV+storage hybrids offers new opportunities Future Research: Where next? Priority areas for hybrid power research.

25 ENERGY STORAGE↗
NASA NTRS1998

Demonstrating the Performance Benefits of the Strutjet RBCC for Space Launch Architectures

The Rocket Based Combined Cycle (RBCC) engine synergistically combines the best elements of airbreathing and rocket propulsion to benefit a wide range of future reusable launch vehicles. Aerojet's Strutjet RBCC offers high I(sub sp) during mid-phase acceleration, and high thrust for boost and final ascent phases. The result is a relatively low gross weight vehicle with lower thrust requirements than comparable all-rocket solutions. Relative to combination propulsion systems, the integrated propulsive elements of the Strutjet reduce engine weight and complexity. In the recent NASA Highly Reusable Space Transportation (HRST) study, vehicles with RBCC-class engines were projected to have lower per flight operations costs than comparable rockets. The more benign operating environment of the RBCC engine primary rockets (2000 psi chamber pressure, lower internal temperatures, gas generator cycle) lead to longer service life, fewer maintenance actions, and increased reliability. Operations costs are typically the most significant contributor to life cycle costs. RBCC-powered vehicles lend themselves naturally to horizontal takeoff, which typically requires less thrust for a given gross vehicle weight when compared to an all-rocket-powered vehicle. The lower thrust requirements reduce engine size and/or quantity, reducing the n of ground personnel and facilities required to maintain the vehicle. The reduced sensitivity to mass fraction also allows the vehicle to be designed with higher margins for improved life and reliability. Because of its multi-mode ascent operation and ability to perform long cruise segments, the strutjet RBCC offers RLV designers a chance to create vehicles with an unprecedented level of mission flexibility. Features such as supersonic cruise, flyback, off-set launch, self-ferry, horizontal takeoff and landing, multi-base operation, and flexible aborts open up a broad range of potential revenue producing missions. The Strutjet can lead to low-cost vehicle designs in traditional areas such as LEO cargo delivery and ISS resupply, and also lead to economically attractive vehicles for small payload missions difficult to achieve with all-rocket solutions. The performance capability of the Strutjet RBCC has been demonstrated in all operating mod underfunding from NASA MSFC and Aerojet as a result of over 1000testsand over 13 years of continuous development-a significant resource investment in the Strutjet engine design.

Johnson, D.↗
NASA NTRS2016

International Space Station Configuration Analysis and Integration

Ambitious engineering projects, such as NASA's International Space Station (ISS), require dependable modeling, analysis, visualization, and robotics to ensure that complex mission strategies are carried out cost effectively, sustainably, and safely. Learn how Booz Allen Hamilton's Modeling, Analysis, Visualization, and Robotics Integration Center (MAVRIC) team performs engineering analysis of the ISS Configuration based primarily on the use of 3D CAD models. To support mission planning and execution, the team tracks the configuration of ISS and maintains configuration requirements to ensure operational goals are met. The MAVRIC team performs multi-disciplinary integration and trade studies to ensure future configurations meet stakeholder needs.

Anchondo, Rebekah↗
NASA NTRSDate not supplied

NICS (NASA Instrument Capabilities Study) Instrument Schedule and Cost Study

This paper summarizes work performed on the Flight Projects Directorate Planetary Science Projects Division (PSPD, Code 430) NICS (NASA Instrument Capabilities study) instrument schedule and cost study. Included are a short summary of the original NICS (NASA, 2008), and the design and approach, data collection, analysis, preliminary findings and recommendations from select areas of the current study. The NICS (2008) was chartered by then NASA Chief Engineer Michael Ryschkewitsch and chaired by Goddard Space Flight Center (GSFC) engineer, John Leon. The focus was to identify problem areas in instrument development and, if possible, to offer solutions. In the area of instrument developments, the NICS (2008) identified a lack of resources and authority to successfully manage to instrument cost and schedule requirements; and a lack of critical skills, expertise, and leadership to successfully implement unique (one-of-a-kind) high technology developments (NASA, 2008, pp. 51, 52). Additionally, the NICS (2008) found problems in requirements formulation, reviews and management; unrealistic caps and overly optimistic estimates; and externally directed changes which increased the likelihood of overrunning cost and schedule (NASA, 2008, pp.53, 54). It is noteworthy that NICS findings are consistent with previous studies at the mission level (Robbins, Schmidt & White, 2020). Five years later in 2013, the Instrument Projects Division (IPD) was established to implement and manage instrument projects greater than $20M. The IPD was known as Code 490. Its structure incorporated several of the NICS (2008) recommendations. To see if these incorporated recommendations made a difference, and to identify other potential challenges in instrument developments, two parallel studies were initiated. Originally led by the IPD, now led by the PSPD, and the Instrument and Payload Systems Engineering Branch (IPSE, Code 592), respectively, the instrument schedule and cost study and the instrument technical complexity study began in 2017. Data collection was initiated in 2020 and is on-going. This paper is limited to the IPD/PSPD study. Among other findings, preliminary data indicate IPD/PSPD project management support positively influenced instrument development as related to providing a dedicated level of support staff, including a deputy Instrument Project Manager (dIPM), reducing IPM leadership changes, and providing other project support. Next steps include continued data collection and analysis, and mapping to technical complexity data.

NICS implementation↗
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 NTRS1999

CVD Rhenium Engines for Solar-Thermal Propulsion Systems

Solar-thermal upper-stage propulsion systems have the potential to provide specific impulse approaching 900 seconds, with 760 seconds already demonstrated in ground testing. Such performance levels offer a 100% increase in payload capability compared to state-of-the-art chemical upper-stage systems, at lower cost. Although alternatives such as electric propulsion offer even greater performance, the 6- to 18- month orbital transfer time is a far greater deviation from the state of the art than the one to two months required for solar propulsion. Rhenium metal is the only material that is capable of withstanding the predicted thermal, mechanical, and chemical environment of a solar-thermal propulsion device. Chemical vapor deposition (CVD) is the most well-established and cost-effective process for the fabrication of complex rhenium structures. CVD rhenium engines have been successfully constructed for the Air Force ISUS program (bimodal thrust/electricity) and the NASA Shooting Star program (thrust only), as well as under an Air Force SBIR project (thrust only). The bimodal engine represents a more long-term and versatile approach to solar-thermal propulsion, while the thrust-only engines provide a potentially lower weight/lower cost and more near-term replacement for current upper-stage propulsion systems.

Williams, Brian E.↗
DOE OSTI2023

Novel Wavefunction Approaches for Studying Actinides and Other Heavy Elements (Final Report (2012-2020))

The theoretical characterization of actinide molecules is a crucial complement to their experimental study; actinides are vital to issues of national security and energy, but they are expensive and hazardous to study experimentally. However, because actinides contain a large number of electrons and are often strongly correlated, their theoretical description is difficult. We have had success studying actinide chemistry and physics using density functional theoretical approaches over the past several years, but we have found that such methods are incapable of treating strong correlations adequately. We thus shifted our research focus to the development of tractable wavefunction methods for strong correlations of actinides. Our early wavefunction-based approaches focused on extending symmetry-adapted, single-reference coupled cluster for treating strong correlations with feasible computational cost. While we have had some success along these lines, we have recently developed spin-projected unrestricted coupled cluster, which is essentially a black-box multi-reference coupled cluster theory that is superior to unrestricted coupled cluster for small- to medium-sized systems across practically all physical correlation strengths, yet preserves good quantum numbers. For actinides, however, where spin-orbit coupling is often nonnegligible, spin is no longer a fundamental symmetry. We thus propose to develop time reversal and point group projected coupled cluster, which will preserve the fundamental symmetries for actinides. Time reversal projection is achieved via the product of half-spin projection, or spin flip, and complex conjugation projection. Along with point group, these are discrete symmetries, i.e. non-continuous quantum numbers, which, in addition to being the correct symmetries for actinides, can be implemented in lower computational cost than full spin projection. We propose the development of these theories within a synergistic collaboration to use the new methods to elucidate difficult actinide chemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part 2

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. Here, a high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine. This paper defines a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute mixtures when properly matched to fuel spray characteristics, injection strategy, and a high-energy ignition system. Boost system layout and base engine architecture were selected to minimize parasitics and maximize after treatment effectiveness. A multi-cylinder engine was developed and calibrated over a steady-state map. Results fed vehicle simulations over the EPA city and highway test cycles to predict the fuel economy improvement and tailpipe emissions potential. Fuel economy improvements over the baseline vehicle were projected at 42% and 39% for active-urea and passive-ammonia SCR after treatment systems respectively. Controls complexity to achieve regulatory compliance and the cost of the lean after treatment system were identified as the primary challenges to commercial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2011

Systems Engineering Using Heritage Spacecraft Technology: Lessons Learned from Discovery and New Frontiers Deep Space Missions

In the design and development of complex spacecraft missions, project teams frequently assume the use of advanced technology or heritage systems to enable a mission or reduce the overall mission risk and cost. As projects proceed through the development life cycle, increasingly detailed knowledge of the advanced or heritage systems and the system environment identifies unanticipated issues that result in cost overruns or schedule impacts. The Discovery & New Frontiers (D&NF) Program Office recently studied cost overruns and schedule delays resulting from advanced technology or heritage assumptions for 6 D&NF missions. The goal was to identify the underlying causes for the overruns and delays, and to develop practical mitigations to assist the D&NF projects in identifying potential risks and controlling the associated impacts to proposed mission costs and schedules. The study found that the cost and schedule growth did not result from technical hurdles requiring significant technology development. Instead, systems engineering processes did not identify critical issues early enough in the design cycle to ensure project schedules and estimated costs address the inherent risks. In general, the overruns were traceable to: inadequate understanding of the heritage system s behavior within the proposed spacecraft design and mission environment; an insufficient level of experience with the heritage system; or an inadequate scoping of the system-wide impacts necessary to implement the heritage or advanced technology. This presentation summarizes the study s findings and offers suggestions for improving the project s ability to identify and manage the risks inherent in the technology and heritage design solution.

Barley, Bryan↗
NASA NTRSDate not supplied

Modified Epoxy Matrix Resins for Reduced Dependence on Redundant Fasteners in Secondary-Bonded Composite Structures

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination that can lead to weak bonds. No methods currently exist to measure the strength of an adhesive bond nondestructively. For these reasons, regulating organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to achieve certification for civil transport aircraft. To meet this requirement, manufacturers commonly install redundant fasteners (~105 fasteners in a twin-aisle airframe with composite fuselage and wings), which add tremendous complexity, time and cost, and significantly reduce performance of the airframe. Under NASA’s Convergent Aeronautics Solutions (CAS) Program, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy matrix resins to enable reflow and diffusion of the resin at the interface during a secondary bonding/cure process. The mixing process eliminates the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion across a nearly two-dimensional boundary. The AERoBOND interface is similar to the interlaminar region formed during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin, which can be measured, inspected non-destructively, and certified for flight with fewer redundant fasteners. This presentation describes the ongoing development of stoichiometrically-offset epoxy resins to control the degree of cure in composite joints and enable interfacial mixing during secondary bonding/curing. Details on the resin formulation, laminate fabrication, and mechanical testing will also be presented. The precracked mode-II fracture toughness measured from preliminary AERoBOND joints was similar for joints fabricated with conventional epoxy matrix materials.

thermoset, hardener, prepreg, assembly↗
DOE OSTI2021

INTEGRATE - Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project is developing a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. This AI-based design technology can capture complex non-linear aerodynamic effects while being 100 times faster than design approaches based on computational fluid dynamics. This project enables innovation in wind turbine design by accelerating time to market through higher-accuracy early design iterations to reduce the levelized cost of energy. INVERTIBLE NEURAL NETWORKS Researchers are leveraging a specialized invertible neural network (INN) architecture along with the novel dimension-reduction methods and airfoil/blade shape representations developed by collaborators at the National Institute of Standards and Technology (NIST) learns complex relationships between airfoil or blade shapes and their associated aerodynamic and structural properties. This INN architecture will accelerate designs by providing a cost-effective alternative to current industrial aerodynamic design processes, including: - Blade element momentum (BEM) theory models: limited effectiveness for design of offshore rotors with large, flexible blades where nonlinear aerodynamic effects dominate - Direct design using computational fluid dynamics (CFD): cost-prohibitive - Inverse-design models based on deep neural networks (DNNs): attractive alternative to CFD for 2D design problems, but quickly overwhelmed by the increased number of design variables in 3D problems AUTOMATED COMPUTATIONAL FLUID DYNAMICS FOR TRAINING DATA GENERATION - MERCURY FRAMEWORK The INN is trained on data obtained using the University of Marylands (UMD) Mercury Framework, which has with robust automated mesh generation capabilities and advanced turbulence and transition models validated for wind energy applications. Mercury is a multi-mesh paradigm, heterogeneous CPU-GPU framework. The framework incorporates three flow solvers at UMD, 1) OverTURNS, a structured solver on CPUs, 2) HAMSTR, a line based unstructured solver on CPUs, and 3) GARFIELD, a structured solver on GPUs. The framework is based on Python, that is often used to wrap C or Fortran codes for interoperability with other solvers. Communication between multiple solvers is accomplished with a Topology Independent Overset Grid Assembler (TIOGA). NOVEL AIRFOIL SHAPE REPRESENTATIONS USING GRASSMAN SPACES We developed a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation as an analytic generative model, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data , (ii) improved low-dimensional parameter domain for inferential statistics informing design/manufacturing, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes. TECHNOLOGY TRANSFER DEMONSTRATION - COUPLING WITH NREL WISDEM Researchers have integrated the inverse-design tool for 2D airfoils (INN-Airfoil) into WISDEM (Wind Plant Integrated Systems Design and Engineering Model), a multidisciplinary design and optimization framework for assessing the cost of energy, as part of tech-transfer demonstration. The integration of INN-Airfoil into WISDEM allows for the design of airfoils along with the blades that meet the dynamic design constraints on cost of energy, annual energy production, and the capital costs. Through preliminary studies, researchers have shown that the coupled INN-Airfoil + WISDEM approach reduces the cost of energy by around 1% compared to the conventional design approach. This page will serve as a place to easily access all the publications from this work and the repositories for the software developed and released through this pr...

aerodynamics↗