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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
DOE OSTI2024

Optimization of Structurally Enhanced Solder Transient Liquid Phase Bonding

High temperature packaging technologies are a necessity for high temperature capable devices. SAC305 solder has an operational limit of 174°C imposed by creep effects which aligns well with current junction temperature limits of 175°C. Wide band gap semiconductor materials have the potential to reach junction temperatures of up to 800°C that are not currently attainable with significant reliability. Capitalizing on this potential will requires substrates and attachments that can operate well beyond the current 175°C standard. Silver sintering pastes have received widespread interest as a high temperature attachment alternative. However, the process requires high pressure bonding in an inert environment to achieve acceptable bond quality. Transient liquid phase (TLP) sintering is capable of good bond quality without pressure requirements but suffers from low thermal conductivity and only slightly reduced cost compared to silver sintering. SAC305 solder contains the same constituent materials for TLP as available copper-tin TLP sintering paste. By introducing engineered surface structures into the bond, intermetallic formation can be accelerated producing a bond similar to TLP sintering but in an ambient environment and for reduced cost. While this process has been demonstrated, it has not yet been optimized. Currently bonds are formed using a 75 μm stencil on substrate surface structures 24 μm tall, covering 19% of the bonding area. The process takes about 4 hours not including the formation of surface structures. Here, this study will center on the effects of stencil thickness and coating methods. Samples will be analyzed by scanning acoustic microscopy, die shear testing and cross sectional scanning acoustic microscopy.

42 ENGINEERING↗
NASA NTRS1991

Designing for Cost

Designing for cost is a state of mind. Of course, a lot of technical knowledge is required and the use of appropriate tools will improve the process. Unfortunately, the extensive use of weight based cost estimating relationships has generated a perception in the aerospace community that the primary way to reduce cost is to reduce weight. Wrong! Based upon an approximation of an industry accepted formula, the PRICE H (tm) production-production equation, Dean demonstrated theoretically that the optimal trajectory for cost reduction is predominantly in the direction of system complexity reduction, not system weight reduction. Thus the phrase "keep it simple" is a primary state of mind required for reducing cost throughout the design process.

Dean, Edwin B.↗
DOE OSTI2020

Multi-functional anodes boost the transient power and durability of proton exchange membrane fuel cells

Abstract Proton exchange membrane fuel cells have been regarded as the most promising candidate for fuel cell vehicles and tools. Their broader adaption, however, has been impeded by cost and lifetime. By integrating a thin layer of tungsten oxide within the anode, which serves as a rapid-response hydrogen reservoir, oxygen scavenger, sensor for power demand, and regulator for hydrogen-disassociation reaction, we herein report proton exchange membrane fuel cells with significantly enhanced power performance for transient operation and low humidified conditions, as well as improved durability against adverse operating conditions. Meanwhile, the enhanced power performance minimizes the use of auxiliary energy-storage systems and reduces costs. Scale fabrication of such devices can be readily achieved based on the current fabrication techniques with negligible extra expense. This work provides proton exchange membrane fuel cells with enhanced power performance, improved durability, prolonged lifetime, and reduced cost for automotive and other applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Highly Efficient Magnetocaloric Natural Gas Liquefaction (Final Report)

Over the twelve-month project the following achievements were accomplished: • Liquefication of methane as primary component of natural gas was accomplished with a magnetocaloric liquefier (MCL) prototype. This was the first time an MCL was used to liquefy methane. • Improved MCL designs were completed. • Cooling to 135 K from room temperature was achieved for the first time in a single MCL stage with dual, reciprocating four-layer regenerators. • Techno-economic analysis for a multi-stage 5 tonne/day magnetocaloric liquefier was completed. The detailed thermodynamic analysis of this MCL design showed a figure of merit (FOM) of 0.6 was achievable. This is a ~2x improvement over current state of the art. • Cost of an efficient 5 tonne/day LNG multi-stage liquefier was projected to be ~$\$$3.1 MM for the 5 tonne/day MCL with achievable design assumptions. • Market study of U.S. merchant LNG demand by energy sector was completed showing that at beginning of 2019, total use was ~2.5 million gallons/day primarily in three sectors that was filled by ~20 small companies in the merchant LNG supply business producing ~2.3 million gpd. These data exclude LNG produced at dedicated peak shaving and large export plants. • Business case for MCL technology based on LNG market study was completed showing the high FOM feature of MCL reduces cost of plant power, and lower capital cost reduces debt repayment and plant depreciation operating expenses. However, today’s demand for U.S. merchant LNG in most sectors is satisfied with conventional technology. Further, with today’s extremely low natural gas (NG) feedstock costs (e.g., ~$\$$1.8/MMBtu), the cost of fuel for NG gensets and for LNG feedstock is already very low. Therefore, possible new merchant LNG liquefier plant developers anticipating demand growth in the transportation, industrial, and electricity generation sectors do not obtain sufficient cost benefits to adopt new, commercially unproven MCL technology. • Other market factors such as remoteness from existing NG pipelines, or unfilled or unsatisfied applications such as boil-off gas re-liquefaction in LNG vessels, or policy factors such as some form of emissions-related fees may make lower capital costs and higher FOM of MCL technology attractive for new small-scale (~50 tonne/day) LNG plants. Two potentially attractive niche markets for MCL technology were identified: i) re-liquefaction of boil-off gas from large LNG transport vessels where severe transport conditions are problematic for conventional technology; and ii) providing LNG in distributed-scale plants that eliminate road transport costs to meet diverse, smaller-scale, distributed LNG bunkering fuel demands. By eliminating significant cryogenic tanker delivery costs and create an attractive cost-savings benefit with small-scale MCL plants.

03 NATURAL GAS↗
DOE OSTI2024

Improved Manufacturability and Throughput of Ultra- Transparent, Super-Insulating Aerogels

AeroShield Materials produces a novel silica aerogel material with exemplary thermal performance and unprecedented optical clarity, offering the potential for super-insulating fenestration and insulated glass to reduce thermal losses in the built environment by billions of dollars every year. One of the most significant challenges facing AeroShield today is the total amount of time that is required to produce large monolithic aerogel samples. This overall process can require as much as 144 hours total, which can significantly hinder scale-up to an economically viable product. The purpose of this Phase 1 research was to continue development of our novel aerogel manufacturing process to reduce material processing time by up to 10x, greatly improving product throughput and reducing cost. AeroShield’s manufacturing process can be divided into 4 major stages, each with their own distinct set of parameters and time requirements. Under this Phase 1 award, AeroShield was able to identify and optimize a number of these parameters, including molding materials, solvent rinse conditions, critical point drying time, and annealing conditions. AeroShield also performed thorough analyses on how these optimized parameters affected important final characteristics of the gels, including optical clarity, thermal conductivity, and dimensional stability. This campaign culminated in the production of laboratory scale aerogel samples using significantly lower process times of both 36 and 18 total hours, which represent Phase 1 Target and Stretch goals. In order to achieve widespread market adoption, monolithic sheets of the aerogel material must be made to industry-standard sizes (8’ x 12’) at a cost that provides 5-7 year or less breakeven energy savings for consumers (<$2 sq/ft). The work performed under this Phase 1 award shows that time and materials required to make aerogel samples, which make up a significant portion of their overall cost, can be greatly reduced without sacrificing quality. AeroShield plans to use these optimized processes to produce larger, product-relevant sized aerogels in order to achieve target final material costs.

Wilke, Kyle↗
NASA NTRS2016

Exploring Cognition Using Software Defined Radios for NASA Missions

NASA missions typically operate using a communication infrastructure that requires significant schedule planning with limited flexibility when the needs of the mission change. Parameters such as modulation, coding scheme, frequency, and data rate are fixed for the life of the mission. This is due to antiquated hardware and software for both the space and ground assets and a very complex set of mission profiles. Automated techniques in place by commercial telecommunication companies are being explored by NASA to determine their usability by NASA to reduce cost and increase science return. Adding cognition the ability to learn from past decisions and adjust behavior is also being investigated. Software Defined Radios are an ideal way to implement cognitive concepts. Cognition can be considered in many different aspects of the communication system. Radio functions, such as frequency, modulation, data rate, coding and filters can be adjusted based on measurements of signal degradation. Data delivery mechanisms and route changes based on past successes and failures can be made to more efficiently deliver the data to the end user. Automated antenna pointing can be added to improve gain, coverage, or adjust the target. Scheduling improvements and automation to reduce the dependence on humans provide more flexible capabilities. The Cognitive Communications project, funded by the Space Communication and Navigation Program, is exploring these concepts and using the SCaN Testbed on board the International Space Station to implement them as they evolve. The SCaN Testbed contains three Software Defined Radios and a flight computer. These four computing platforms, along with a tracking antenna system and the supporting ground infrastructure, will be used to implement various concepts in a system similar to those used by missions. Multiple universities and SBIR companies are supporting this investigation. This paper will describe the cognitive system ideas under consideration and the plan for implementing them on platforms, including the SCaN Testbed. Discussions in the paper will include how these concepts might be used to reduce cost and improve the science return for NASA missions.

transmitters receivers↗
DOE OSTI2022

Reducing the cost of energy estimation in the variational quantum eigensolver algorithm with robust amplitude estimation

Quantum chemistry and materials is one of the most promising applications of quantum computing. Yet much work is still to be done in matching industry-relevant problems in these areas with quantum algorithms that can solve them. Most previous efforts have carried out resource estimations for quantum algorithms run on large-scale fault-tolerant architectures, which include the quantum phase estimation algorithm. In contrast, few have assessed the performance of near-term quantum algorithms, which include the variational quantum eigensolver (VQE) algorithm. Recently, a large-scale benchmark study [Gonthier et al. 2020] found evidence that the performance of the variational quantum eigensolver for a set of industry-relevant molecules may be too inefficient to be of practical use. This motivates the need for developing and assessing methods that improve the efficiency of VQE. In this work, we predict the runtime of the energy estimation subroutine of VQE when using robust amplitude estimation (RAE) to estimate Pauli expectation values. Under conservative assumptions, our resource estimation predicts that RAE can reduce the runtime over the standard estimation method in VQE by one to two orders of magnitude. Despite this improvement, we find that the runtimes are still too large to be practical. These findings motivate two complementary efforts towards quantum advantage: 1) the investigation of more efficient near-term methods for ground state energy estimation and 2) the development of problem instances that are of industrial value and classically challenging, but better suited to quantum computation.

Johnson, Peter D.↗
DOE OSTI2020

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗
DOE OSTI2021

Review of heat transfer enhancement techniques in two-phase flows for highly efficient and sustainable cooling

We show that two-phase internal flow is ubiquitous to many systems due to its ability to transfer large amounts of heat effectively. Recent advances motivated by sustainability have pushed towards augmenting the heat transfer between the tube and the two-phase working fluid. Augmenting heat transfer in two-phase flows enables process intensification, and compactness leading to reduced cost and material consumption. This review investigates the effect of heat transfer enhancement techniques on different fluids including R134a, R407C, R22, etc … The techniques are categorized into passive and active and focus on durable enhancement methods which do not include surface structuring or coating. Passive techniques utilize geometrical and surface modifications to induce better mixing. Several passive techniques are analyzed including fins, inserts, and more. In analyzing these techniques, the effect of changing geometric parameters is studied, and the limitations are highlighted. Further, active techniques that enable heat transfer enhancement through applying power are also investigated. Electrohydrodynamic approaches are analyzed and compared to passive techniques. Additionally, the implications of heat exchange enhancement in the context of global energy are discussed. An energy analysis discretized by the use sector is conducted, with an emphasis on predicting the future potential for renewable and sustainable development. Moreover, although active approaches provide the highest heat transfer enhancement, due to implementation difficulties, passive techniques are more frequently adopted. The review ends with discussion of next-generation heat exchangers which will rely more on additive manufacturing due to its flexibility and reduced cost per part as the technology matures.

Nusselt number↗
DOE OSTI2023

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗
DOE OSTI2021

The Impact of Behind-the-Meter Heterogeneous Distributed Energy Resources on Distribution Grids

The increasing integration of distributed energy resources (DERs) on the electric grid brings new challenges and opportunities for utility grid operations. With the rapid deployment of DERs, there is emerging interest in integrating these controllable devices with utility operations at all levels for monitoring and management. To understand the challenges with increasing behind-the-meter (BTM) DERs and to identify the needs in deploying advanced controls, a comprehensive grid impact study is indispensable. This paper presents the analysis which help visualize the DER impact on the grid, identify the challenges and provides an insight into the new distribution management and control needs to enable reliable and resilient grid operations.

behind-the-meter↗
NASA NTRS1998

Information Systems for NASA's Aeronautics and Space Enterprises

The aerospace industry is being challenged to reduce costs and development time as well as utilize new technologies to improve product performance. Information technology (IT) is the key to providing revolutionary solutions to the challenges posed by the increasing complexity of NASA's aeronautics and space missions and the sophisticated nature of the systems that enable them. The NASA Ames vision is to develop technologies enabling the information age, expanding the frontiers of knowledge for aeronautics and space, improving America's competitive position, and inspiring future generations. Ames' missions to accomplish that vision include: 1) performing research to support the American aviation community through the unique integration of computation, experimentation, simulation and flight testing, 2) studying the health of our planet, understanding living systems in space and the origins of the universe, developing technologies for space flight, and 3) to research, develop and deliver information technologies and applications. Information technology may be defined as the use of advance computing systems to generate data, analyze data, transform data into knowledge and to use as an aid in the decision-making process. The knowledge from transformed data can be displayed in visual, virtual and multimedia environments. The decision-making process can be fully autonomous or aided by a cognitive processes, i.e., computational aids designed to leverage human capacities. IT Systems can learn as they go, developing the capability to make decisions or aid the decision making process on the basis of experiences gained using limited data inputs. In the future, information systems will be used to aid space mission synthesis, virtual aerospace system design, aid damaged aircraft during landing, perform robotic surgery, and monitor the health and status of spacecraft and planetary probes. NASA Ames through the Center of Excellence for Information Technology Office is leading the effort in pursuit of revolutionary, IT-based approaches to satisfying NASA's aeronautics and space requirements. The objective of the effort is to incorporate information technologies within each of the Agency's four Enterprises, i.e., Aeronautics and Space Transportation Technology, Earth, Science, Human Exploration and Development of Space and Space Sciences. The end results of these efforts for Enterprise programs and projects should be reduced cost, enhanced mission capability and expedited mission completion.

Kutler, Paul↗
NASA NTRS2016

Additive Manufacturing for Affordable Rocket Engines

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch labor required, and increases reliability. When certification is achieved, NASA missions will be able to realize these benefits.

West, Brian↗
DOE OSTI2026

Dynamic analysis of fully constrained Cable-Driven Parallel Robots for automated prefabricated component installation

This paper presents a dynamic analysis and validation framework to assess a fully constrained six-anchor Cable-Driven Parallel Robot (CDPR) for automated installation of prefabricated facade components. Compared with conventional eight-anchor systems, the six-anchor configuration simplifies setup and reduces cost, but it also reduces control authority, shrinks the wrench-feasible workspace, and tightens orientation limits. Consequently, it is unclear a priori whether dynamically feasible trajectories exist to move the end effector from pickup to the facade. A constrained trajectory optimization is formulated to enforce the system dynamics, cable-tension bounds, and pose/velocity limits, and the framework is evaluated in simulation at three levels: (i) an idealized reference model, (ii) a lab-scale prototype model incorporating measured anchor misalignments and identified damping, and (iii) a full-scale three-story building model with load decomposition for structural feasibility checks. Across these scenarios, the analysis shows that optimal, constraint-satisfying trajectories exist that move the end effector from pickup to installation while maintaining a near-plumb, level orientation at the final pose. Collectively, this multi-scale dynamic analysis and validation framework supports the deployment readiness of the six-anchor CDPR and provides a prototype-based sensitivity case study of how measured anchor placement deviations affect feasibility.

CDPR↗