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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

SSME LOX post flow analysis/fluid structure interaction. Volume 1: Flow analysis

The realization of measures to improve the performance of the Space Shuttle is, to a large extent, dependent on an improved understanding of the fluid flow phenomena occurring in the main engine. The overall arrangement of the primary components of the Space Shuttle Main Engine (SSME) are presented. The impingement of the hot gases from the transfer ducts onto the LOX posts causes them to be subjected to severe thermal and gas dynamic loads, which in the past have resulted in the occasional breakage of some elements of the outer row of posts during test firings of the engine, particularly at higher power levels. Large velocities in the gap between the LOX posts may also be a contributing factor in causing dynamic stability problems. The deforming structural response of the posts to the pressure loading may likely affect the gas flowfield by producing a moving flowfield boundary, thereby creating a dynamically coupled unsteady fluid-structure system. The objective was to investigate the three-dimensional, turbulent flow around a simplified SSME LOX post array using an existing Reynolds averaged Navier-Stokes flow solver and a suitable turbulence model to parameterize the turbulent shear stresses. Numerical computations were performed to analyze the effect on the flowfield of varying the spacing between the LOX posts, which were modeled as rigid, three-dimensional circular cylinders. The methodology used in the computations is described. Results are presented.

Burke, Roger W.↗
DOE OSTI2025

Innovative Symmetrical Electrolyte Architecture Enables Ultra-Flat and Thermal Resilient Protonic Ceramic Electrochemical Cells

Protonic ceramic electrochemical cells (PCECs) represent a promising class of solid‐state energy conversion devices capable of high‐efficiency hydrogen production and power generation. However, the practical deployment of planar PCECs is fundamentally constrained by severe structural deformation and mechanical failure during fabrication, stemming from asymmetric shrinkage between the thin electrolyte and the thick NiO‐based support layer. Here, in this work, a functionally integrated, symmetry‐engineered double‐sided electrolyte (DE) design is unveiled, which not only suppresses thermally induced curvature but also unlocks significant gains in electrochemical performance and stability. This architecture intrinsically balances shrinkage dynamics across the cell bilaterally, enabling the fabrication of ultra‐flat 5 × 5 cm 2 cells with sub‐100 µm thickness variation. A numerical solid mechanics simulation is introduced to investigate and interpret this achievement. Beyond structural advantages, the DE configuration enhances the cell operational stability, delivering a low open‐circuit voltage degradation of 9.5 mV/100 h across 80 thermal cycles. This work establishes a compelling paradigm wherein architectural symmetry directly translates to both mechanical fidelity and functional enhancement, offering a promising route toward PCECs scale‐up.

08 - HYDROGEN↗
DOE OSTI2022

Native lattice strain induced structural earthquake in sodium layered oxide cathodes

Abstract High-voltage operation is essential for the energy and power densities of battery cathode materials, but its stabilization remains a universal challenge. To date, the degradation origin has been mostly attributed to cycling-initiated structural deformation while the effect of native crystallographic defects induced during the sophisticated synthesis process has been significantly overlooked. Here, using in situ synchrotron X-ray probes and advanced transmission electron microscopy to probe the solid-state synthesis and charge/discharge process of sodium layered oxide cathodes, we reveal that quenching-induced native lattice strain plays an overwhelming role in the catastrophic capacity degradation of sodium layered cathodes, which runs counter to conventional perception—phase transition and cathode interfacial reactions. We observe that the spontaneous relaxation of native lattice strain is responsible for the structural earthquake (e.g., dislocation, stacking faults and fragmentation) of sodium layered cathodes during cycling, which is unexpectedly not regulated by the voltage window but is strongly coupled with charge/discharge temperature and rate. Our findings resolve the controversial understanding on the degradation origin of cathode materials and highlight the importance of eliminating intrinsic crystallographic defects to guarantee superior cycling stability at high voltages.

25 ENERGY STORAGE↗
NASA NTRS2014

Aerostructural Level Set Topology Optimization for a Common Research Model Wing

The purpose of this work is to use level set topology optimization to improve the design of a representative wing box structure for the NASA common research model. The objective is to minimize the total compliance of the structure under aerodynamic and body force loading, where the aerodynamic loading is coupled to the structural deformation. A taxi bump case was also considered, where only body force loads were applied. The trim condition that aerodynamic lift must balance the total weight of the aircraft is enforced by allowing the root angle of attack to change. The level set optimization method is implemented on an unstructured three-dimensional grid, so that the method can optimize a wing box with arbitrary geometry. Fast matching and upwind schemes are developed for an unstructured grid, which make the level set method robust and efficient. The adjoint method is used to obtain the coupled shape sensitivities required to perform aerostructural optimization of the wing box structure.

Dunning, Peter D.↗
NASA NTRS2012

Instrumentation for the Characterization of Inflatable Structures

Current entry, descent, and landing technologies are not practical for heavy payloads due to mass and volume constraints dictated by limitations imposed by launch vehicle fairings. Therefore, new technologies are now being explored to provide a mass- and volume-efficient solution for heavy payload capabilities, including Inflatable Aerodynamic Decelerators (IAD) [1]. Consideration of IADs for space applications has prompted the development of instrumentation systems for integration with flexible structures to characterize system response to flight-like environment testing. This development opportunity faces many challenges specific to inflatable structures in extreme environments, including but not limited to physical flexibility, packaging, temperature, structural integration and data acquisition [2]. In the spring of 2012, two large scale Hypersonic Inflatable Aerodynamic Decelerators (HIAD) will be tested in the National Full-Scale Aerodynamics Complex s 40 by 80 wind tunnel at NASA Ames Research Center. The test series will characterize the performance of a 3.0 m and 6.0 m HIAD at various angles of attack and levels of inflation during flight-like loading. To analyze the performance of these inflatable test articles as they undergo aerodynamic loading, many instrumentation systems have been researched and developed. These systems will utilize new experimental sensing systems developed by the HIAD ground test campaign instrumentation team, in addition to traditional wind tunnel sensing techniques in an effort to improve test article characterization and model validation. During the 2012 test series the instrumentation systems will target inflatable aeroshell static and dynamic deformation, structural strap loading, surface pressure distribution, localized skin deflection, and torus inflation pressure. This paper will offer an overview of inflatable structure instrumentation, and provide detail into the design and implementation of the sensors systems that will be utilized during the 2012 HIAD ground test campaign.

Swanson, Gregory T.↗
NASA NTRS1996

Optimal Output Trajectory Redesign for Invertible Systems

Given a desired output trajectory, inversion-based techniques find input-state trajectories required to exactly track the output. These inversion-based techniques have been successfully applied to the endpoint tracking control of multijoint flexible manipulators and to aircraft control. The specified output trajectory uniquely determines the required input and state trajectories that are found through inversion. These input-state trajectories exactly track the desired output; however, they might not meet acceptable performance requirements. For example, during slewing maneuvers of flexible structures, the structural deformations, which depend on the required state trajectories, may be unacceptably large. Further, the required inputs might cause actuator saturation during an exact tracking maneuver, for example, in the flight control of conventional takeoff and landing aircraft. In such situations, a compromise is desired between the tracking requirement and other goals such as reduction of internal vibrations and prevention of actuator saturation; the desired output trajectory needs to redesigned. Here, we pose the trajectory redesign problem as an optimization of a general quadratic cost function and solve it in the context of linear systems. The solution is obtained as an off-line prefilter of the desired output trajectory. An advantage of our technique is that the prefilter is independent of the particular trajectory. The prefilter can therefore be precomputed, which is a major advantage over other optimization approaches. Previous works have addressed the issue of preshaping inputs to minimize residual and in-maneuver vibrations for flexible structures; Since the command preshaping is computed off-line. Further minimization of optimal quadratic cost functions has also been previously use to preshape command inputs for disturbance rejection. All of these approaches are applicable when the inputs to the system are known a priori. Typically, outputs (not inputs) are specified in tracking problems, and hence the input trajectories have to be computed. The inputs to the system are however, difficult to determine for non-minimum phase systems like flexible structures. One approach to solve this problem is to (1) choose a tracking controller (the desired output trajectory is now an input to the closed-loop system and (2) redesign this input to the closed-loop system. Thus we effectively perform output redesign. These redesigns are however, dependent on the choice of the tracking controllers. Thus the controller optimization and trajectory redesign problems become coupled; this coupled optimization is still an open problem. In contrast, we decouple the trajectory redesign problem from the choice of feedback-based tracking controller. It is noted that our approach remains valid when a particular tracking controller is chosen. In addition, the formulation of our problem not only allows for the minimization of residual vibration as in available techniques but also allows for the optimal reduction fo vibrations during the maneuver, e.g., the altitude control of flexible spacecraft. We begin by formulating the optimal output trajectory redesign problem and then solve it in the context of general linear systems. This theory is then applied to an example flexible structure, and simulation results are provided.

Devasia, S.↗
NASA NTRS2015

Development of a SMA-Based, Slat-Gap Filler for Airframe Noise Reduction

Noise produced by unsteady flow around aircraft structures, termed airframe noise, is an important source of aircraft noise during the approach and landing phases of flight. Conventional leading-edge-slat devices for high lift on typical transport aircraft are a prominent source of airframe noise. Many concepts for slat noise reduction have been investigated. Slat-cove fillers have emerged as an attractive solution, but they maintain the gap flow, leaving some noise production mechanisms unabated, and thus represent a nonoptimal solution. Drooped-leading-edge (DLE) concepts have been proposed as "optimal" because the gap flow is eliminated. The deployed leading edge device is not distinct and separate from the main wing in DLE concepts and the high-lift performance suffers at high angles of attack (alpha) as a consequence. Elusive high-alpha performance and excessive weight penalty have stymied DLE development. The fact that high-lift performance of DLE systems is only affected at high alpha suggests another concept that simultaneously achieves the high-lift of the baseline airfoil and the noise reduction of DLE concepts. The concept involves utilizing a conventional leading-edge slat device and a deformable structure that is deployed from the leading edge of the main wing and closes the gap between the slat and main wing, termed a slat-gap filler (SGF). The deployable structure consists of a portion of the skin of the main wing and it is driven in conjunction with the slat during deployment and retraction. Benchtop models have been developed to assess the feasibility and to study important parameters. Computational models have assisted in the bench-top model design and provided valuable insight in the parameter space as well as the feasibility.

Turner, Travis L.↗
NASA NTRS2021

Application of a Developmental Composite Material Model to Predict the Crush Response of Two Energy Absorbers

In 2012, a consortium was formed with the goal of creating a new composite material model capable of predicting the wide range of properties, accumulated damage behavior, and the many different types of failure in composites under impact loading. The material model was developed for execution in the commercially available nonlinear, explicit transient dynamic finite element code, LS-DYNA®. This material model incorporates three sub-models: deformation, damage, and failure. In addition, the model accounts for strain rate and temperature effects and relies heavily on the input of tabulated material response data. The model is designated *MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE, or *MAT_213. Initially, *MAT_213 was developed for use with solid elements only; however, a thin shell element formulation for *MAT_213 has been adapted recently. The objective of this project was to find a suitable modeling example to investigate the capabilities and performance of *MAT_213. In 2012, two composite energy absorbers were designed and evaluated at NASA Langley Research Center through multi-level testing and simulation. The first was a conical-shaped energy absorber, designated the conusoid, which consisted of four layers of hybrid carbon-Kevlar® plain-weave fabric oriented at [+45°/-45°/-45°/+45°] with respect to the vertical direction. The second was a sinusoidal-shaped energy absorber, designated the sinusoid, which consisted of hybrid carbon-Kevlar® plain-weave fabric face sheets, two layers for each face sheet oriented at ±45° with respect to the vertical direction, and a closed-cell ELFOAM® P200 polyisocyanurate foam core. Finite element models were developed of the energy absorbers and simulations were performed using LS-DYNA®. In this paper, the development of a *MAT_213 model of a hybrid carbon-Kevlar® plain-weave fabric is presented. Next, comparisons with material characterization tests are presented. Then, test-analysis results are documented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading using the *MAT_213 material model. Since a prior *MAT_58, or *MAT_LAMINATED_COMPOSITE_FABRIC material model was used in previous simulations of the energy absorbers, comparisons are made between *MAT_58 and *MAT_213 model predictions with test data. Finally, the paper includes a comprehensive list of “lessons learned,” in which a series of parametric studies are documented that were performed to investigate specific issues related to the material model. These “lessons learned” are included in hopes that they may help future *MAT_213 users.

crashworthiness, LS-DYNA transient dynamic simulat↗
DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗
DOE OSTI2021

Methane Adsorption on Heteroatom-Modified Maquettes of Porous Carbon Surfaces

Experimental and theoretical studies disagree on the energetics of methane adsorption on carbon materials. However, this information is critical for the rational design and optimization of the structure and composition of adsorbents for natural gas storage. The delicate nature of dispersion interactions, polarization of both the adsorbent and the adsorbate, interplay between H-bonding and tetrel bonding, and induced dipole/Coulomb interactions inherent to methane physisorption require computational treatment at the highest possible level of theory. In this study, we employed the smallest reasonable computational model, a maquette of porous carbon surfaces with a central site for substitution and methane binding. The most accurate predictions of methane adsorption energetics were achieved by electron-correlated molecular orbital theory CCSD(T) and hybrid density functional theory MN15 calculations employing a saturated, all-electron basis set. Here, the characteristic geometry of methane adsorption on a carbon surface (“lander approach”) arises due to bonding interactions of the adsorbent π-system with the proximal H–C bonds of methane, in addition to tetrel bonding between the antibonding orbital of the distal C–H bond and the central atom of the maquette (C, B, or N). The polarization of the electron density, structural deformations, and the comprehensive energetic analysis clearly indicate a ∼3 kJ mol –1 preference for methane binding on the N-substituted maquette. The B-substituted maquette showed a comparable or lower binding energy than the unsubstituted, pure C model, depending on the level of theory employed. The calculated thermodynamic results indicate a strategy for incorporating electron-enriched substitutions (e.g., N) into carbon materials as a way to increase methane storage capacity over electron-deficient (e.g., B) modifications. The thermochemical analysis was revised for establishing a conceptual agreement between the experimental isosteric heat of adsorption and the binding enthalpies from statistical thermodynamics principles.

03 NATURAL GAS↗
DOE OSTI2024

Material Characterization Study of Magnetite Nanocrystals for RF Sensing

Magnetite nanocrystals show promise for electrically small gigahertz frequency applications, which could lead to miniaturizing transformer cores and new sensing technologies. This work presents a rigorous radiofrequency characterization of these nanocrystals using vector network analyzer (VNA) ferromagnetic resonance (FMR) measurements. For the first time, two different average diameters of Fe 3 O 4 nanocrystals are investigated (7.3 and 20.2 nm). When the VNA–FMR results were compared to micromagnetic simulations, the magnetic anisotropy (K 1 ) deviated from the ideal mean orientation value of K 1 /2 to K 1 /80 for the 7.3 nm nanocrystal. In contrast, the obtained magnetic anisotropy in 20.2 nm nanocrystals slightly deviated to K 1 /11 due to less structural deformations. These findings resulted in a newly proposed methodology for an approximate simulation based on VNA–FMR measurements. In addition, this work estimates the approximate amount of nanocrystals needed to measure a useful VNA–FMR spectrum.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Simulating Sea-Ice Deformation in Viscous-Plastic Sea-Ice Models With CD-Grids

Linear kinematic features (LKFs) are found everywhere in the Arctic sea-ice cover. They are strongly localized deformations often associated with the formation of leads and pressure ridges. In viscous-plastic (VP) sea-ice models, the simulation of LKFs depends on several factors such as the grid resolution, the numerical solver convergence, and the placement of the variables on the mesh. In this study, we compare two recently proposed discretization with a CD-grid placement with respect to their ability to reproduce LKFs. The first (CD1) is based on a nonconforming finite element discretization, whereas the second (CD2) uses a conforming subgrid discretization. To analyze their resolution properties, we evaluate runs from different models (e.g., FESOM, MPAS) on a benchmark problem using quadrilateral, hexagonal and triangular meshes. Our findings show that the CD1 setup simulates more deformation structure than the CD2 setup. This highlights the importance of the type of spatial discretization for the simulation of LKFs. Due to the higher number of degrees of freedom, both CD-grids resolve more LKFs than traditional A, B, and C-grids at fixed mesh level. This is an advantage of the CD-grid approach, as high spatial mesh resolution is needed in VP sea-ice models to simulate LKFs.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Impact of dual-layer solid-electrolyte interphase inhomogeneities on early-stage defect formation in Si electrodes

While intensive efforts have been devoted to studying the nature of the solid-electrolyte interphase (SEI), little attention has been paid to understanding its role in the mechanical failures of electrodes. Here we unveil the impact of SEI inhomogeneities on early-stage defect formation in Si electrodes. Buried under the SEI, these early-stage defects are inaccessible by most surface-probing techniques. With operando full field diffraction X-ray microscopy, we observe the formation of these defects in real time and connect their origin to a heterogeneous degree of lithiation. This heterogeneous lithiation is further correlated to inhomogeneities in topography and lithium-ion mobility in both the inner- and outer-SEI, thanks to a combination of operando atomic force microscopy, electrochemical strain microscopy and sputter-etched X-ray photoelectron spectroscopy. Our multi-modal study bridges observations across the multi-level interfaces (Si/LixSi/inner-SEI/outer-SEI), thus offering novel insights into the impact of SEI homogeneities on the structural stability of Si-based lithium-ion batteries. Severe structural deformation during (de)lithiation is the main factor limiting the stability of Si anodes in Li-ion batteries. Here, a multi-modal approach is used to visualize these deformations in their early-stage and link them to inhomogeneities in the dual-layer solid-electrolyte interphase.

25 ENERGY STORAGE↗
DOE OSTI2023

Selective sorption of oxygen and nitrous oxide by an electron donor-incorporated flexible coordination network

Incorporating strong electron donor functionality into flexible coordination networks is intriguing for sorption applications due to a built-in mechanism for electron-withdrawing guests. Here we report a 2D flexible porous coordination network, [Ni 2 (4,4'-bipyridine)(VTTF) 2 ]n(1) (where H 2 VTTF = 2,2;-[1,2-bis(4-benzoic acid)-1,2ethanediylidene]bis-1,3-benzodithiole), which exhibits large structural deformation from the as-synthesized or open phase (1α) into the closed phase (1β) after guest removal, as demonstrated by X-ray and electron diffraction. Interestingly, upon exposure to electron-withdrawing species, 1β reversibly undergoes guest accommodation transitions; 1α$\supset$O 2 (90 K) and 1α$\supset$N 2 O (185 K). Moreover, the 1β phase showed exclusive O 2 sorption over other gases (N 2 , Ar, and CO) at 120 K. The phase transformations between the 1α and 1β phases under these gases were carefully investigated by in-situ X-ray diffraction, in-situ spectroscopic studies, and DFT calculations, validating that the unusual sorption was attributed to the combination of flexible frameworks and VTTF (electron-donor) that induces strong interactions with electron-withdrawing species.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Device and material investigations of GaN enhancement-mode transistors for Venus and harsh environments

This Letter reports the device and material investigations of enhancement-mode p-GaN-gate AlGaN/GaN high electron mobility transistors (HEMTs) for Venus exploration and other harsh environment applications. The GaN transistor in this work was subjected to prolonged exposure (11 days) in a simulated Venus environment (460 °C, 94 bar, complete chemical environment including CO2/N2/SO2). The mechanisms affecting the transistor performance and structural integrity in harsh environment were analyzed using a variety of experimental, simulation, and modeling techniques, including in situ electrical measurement (e.g., burn-in) and advanced microscopy (e.g., structural deformation). Through transistor, Transmission Line Method (TLM), and Hall-effect measurements vs temperature, it is revealed that the mobility decrease is the primary cause of reduction of on-state performance of this GaN transistor at high temperature. Material analysis of the device under test (DUT) confirmed the absence of foreign elements from the Venus atmosphere. No inter-diffusion of the elements (including the gate metal) was observed. The insights of this work are broadly applicable to the future design, fabrication, and deployment of robust III-N devices for harsh environment operation.

Physics↗
DOE OSTI2024

Modeling of Sagging for 3D Printed Layers During the Curing Process

Here, a printed layer of silica-enforced poly(dimethylsiloxane)-co-(diphenylsiloxane) is modeled as a two-phase system consisting of air and polymer with an interface set up during the printing process. The structural geometry changes mostly due to the action of surface tension, while all material properties are strongly temperature dependent. Polymer flow is described using equations of the extended Herschel–Bulkley model, with parameters strongly dependent on temperature and degree of curing. Parameters of the model are determined using flow sweep measurements and separate experiments with vertical structure sagging at different temperatures. The curing process is modeled using dependencies between the curing rate, degree of curing, and temperature obtained in studies by differential scanning calorimetry. The developed model is used for simulations of printed structure deformations with different initial and boundary conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Pulse Strengthened and Laser Edge Sealed Vacuum Insulation Glazing

A scalable, low-cost processing strategy for glass strengthening and sealing is proposed to improve the thermal performance of insulating glass units and develop innovative window technologies. In this project, a combination of large area photonic processing, additive manufacturing, and laser encapsulation techniques is reported to realize a vacuum glazing technology to meet the cost, performance, reliability, and throughput demands. A modeling framework for evaluating the mechanical and thermal response was established to verify the structural deformation and thermal conductance. Micro-size glass frits in printing ink and a continuous-wave laser curing were employed to allow the formation of a hermetic bonding layer and led to improvement of glass edge sealing. Various sealing parameters, including laser traveling speed, spot diameter, and laser power were optimized. The water seepage and mechanical strength of the resulting glass-to-glass bonding were examined as well. These results showcase the development of a practical vacuum insulating glazing with several unique features through a combination of photonic processing, laser encapsulation, and additive manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗