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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

Low cost carbon fiber as potential lightning strike protection for wind turbine blades

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP have become the integral part of load bearing structures in the blade. In this work, we are proposing to utilize the low cost carbon fiber (LCCF), manufactured at Carbon Fiber Technology Facility (CFTF) of Oak Ridge National Laboratory (ORNL) as not only the cost effective alternative to the currently used carbon fiber (CF) but also as the lightning strike protection of the wind turbine blades. Wind turbines often get hit by lightning strikes due to their operating locations. LCCF can provide structural integrity to these gigantic structures and mitigate the effect of lightning strike on them by effectively dissipating the current. Two composite panels made of LCCF were tested against artificial lightning strikes of 100 kA and 200 kA (component A of lightning waveform SAE ARP 5412-B). The results showed very high resilience of LCCF composite due to their high electrical conductivity both in-plane and in through-thickness directions. There was no significant damage (fiber breakage, resin evaporation or delamination) in both the cases.

Kumar, Vipin↗

Wind Energy Supply Chain Deep Dive Assessment

The Wind Energy Supply Chain Deep Dive Assessment finds that the U.S. wind supply chain is nascent for offshore wind and mature for land-based wind, but U.S. competitiveness is declining in key wind turbine components. Continued decarbonization of the U.S. grid and economy with domestically supplied wind technology will require innovation to increase U.S. manufacturing competitiveness; investment in logistics and infrastructure, such as offshore wind ports and vessels; and policies to provide a strong and stable demand signal to support accelerated investment in the wind supply chain.

17 WIND ENERGY↗

Large, low cost composite wind turbine blades

A woven roving E-glass tape, having all of its structural fibers oriented across the tape width was used in the manufacture of the spar for a wind turbine blade. Tests of a 150 ft composite blade show that the transverse filament tape is capable of meeting structural design requirements for wind turbine blades. Composite blades can be designed for interchangeability with steel blades in the MOD-1 wind generator system. The design, analysis, fabrication, and testing of the 150 ft blade are discussed.

Gewehr, H. W.↗

2022 System Optimization Awardee: XFlow Energy Company

Vertical-axis wind turbines offer several cost-saving advantages over traditional horizontal-axis wind turbines, including lower blade manufacturing costs and a simpler mechanical design. Unfortunately, until now, vertical configurations have not been able to match the power production and durability of more conventional horizontal-axis models. XFlow Energy Company (XFlow Energy) plans to improve the design and reduce the production costs of its 25-kilowatt (kW) vertical-axis wind turbine, delivering a levelized cost of energy that is competitive with that of U.S. retail electricity generated by coal-fired power plants. XFlow Energy's efficient turbine also is designed to maximize power production and longevity. Two previous Competitiveness Improvement Project (CIP) awards funded XFlow Energy's development of a 10-meter vertical-axis turbine prototype.

CIP↗

Wind Turbine Blade Finishing Automation: Robotic Toolpath Generation

Wind turbine blades are now over 100 meters long and can reach heights of several meters while in the finishing area of the factory. Because of this, automation should be used to lower the manufacturing cost and make the process safer for blade manufacturing technicians. This session will present a novel method that generates a six degree of freedom robotic toolpath with 3D cameras for the finishing of wind turbine blades to drive down the levelized cost and make wind energy even more competitive in the utility scale energy generation industry.

3d imaging↗

Mechanism Analysis of Wind Turbine Var Oscillations

Electromagnetic transient simulation of parallel connected 4-MW type-3 wind turbines based on original equipment manufacturer's real-code turbine model shows 1.2-Hz turbine-turbine oscillations in reactive power. This letter reveals why such oscillations occur in the individual var measurement, while being insignificant in the total var measurement, regardless of the varying grid impedance. We adopt two analysis approaches: open-loop single-input single-output analysis and network decomposition. The two approaches differ in their treatment of turbine-network interaction. The open-loop analysis shows that the turbine-turbine oscillation mode is due to an open-loop system pole being attracted to an open-loop system zero. Furthermore, we use network decomposition method to explain why this mode is observable in individual vars while not observable in the total var. The entire system of n -turbines can be viewed as n decoupled circuits. For the two-turbine case, the system has an aggregated mode and a turbine-turbine oscillation mode. Here, the aggregated mode is associated with a circuit associated with the total var, while the turbine-turbine oscillation mode is associated with the var difference and is insensitive to the grid parameters.

17 WIND ENERGY↗

Wind Tunnel Experiment of Microjet-based Flow Control on a Multi-Element High-Lift Airfoil

A wind tunnel model was designed, manufactured, and tested to evaluate the potential of active aerodynamic flow control for multi-element airfoils. The active flow control system involves so-called microjets –small, low momentum, normal to the surface jets located near the trailing edge of the flap –for controlling the lift and improving the aerodynamic performance characteristics of airplane high-lift systems. The configuration selected for this test is the NLR7301 two-element airfoil and it was tested in the Oran W. Nicks Low-Speed Wind Tunnel at Texas A&M University at a chord Reynolds number of 2.0 million and Machnumber of 0.10. This paper presents wind tunnel results for the NLR7301 in the Flap 20 and Flap 30 configurations. The wind tunnel results include surface pressure distributions, lift and pitching moment, and flow visualizations.The results of this experiment validate the effectiveness of the microjet with regards to control of lift in the linear regime for multi-element airfoils.

ARMD↗

Large Horizontal-Axis Wind Turbines

The proceedings of a workshop held in Cleveland, July 28-30, 1981 are described. The workshop emphasized recent experience in building and testing large propeller-type wind turbines, expanding upon the proceedings of three previous DOE/NASA workshops at which design and analysis topics were considered. A total of 41 papers were presented on the following subjects: current and advanced large wind turbine systems, rotor blade design and manufacture, electric utility activities, research and supporting technology, meteorological characteristics for design and operation, and wind resources assessments for siting.

Thresher, R. W.↗

A systems engineering vision for floating offshore wind cost optimization

The U.S. offshore wind resource potential is immense, and often in close proximity to densely-populated coastal load centers. In many U.S. coastal areas, water depths favor the deployment of floating over fixed-bottom offshore wind technology. Floating offshore wind plants have the potential to be cost-competitive with fixed-bottom installations, but because the technology has not yet been deployed at commercial scale, it is not clear when and with what configurations this potential cost parity can be achieved. This article first reviews the state of floating offshore wind technology and deployments to identify key gaps that must be addressed to bring down the overall cost of energy produced. The article then puts forth a long-term vision for a research program and design methodology that may be able to push floating wind plants toward a lower levelized cost of energy than fixed-bottom offshore wind. The method involves a fully integrated systems-engineering and techno-economic design approach to capture the complex interactions between the physics, manufacturing, installation, and operation of floating wind turbines to achieve transformational cost reductions. The approach also envisions multifidelity and uncertainty management strategies to examine the most robust and viable concepts in the design trade-space. To better focus the computational resources, engineering lessons learned from existing offshore wind systems and concept studies are used to develop a set of criteria that can be applied to prefilter candidate technology building blocks that have the greatest cost reduction potential.

17 WIND ENERGY↗

Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D) (Final Technical Report)

As the U.S clean energy transition hinges on the growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements to enable robust and cost-competitive wind turbines. The race to build larger and taller turbines rated 10 megawatts (MW) and beyond, has intensified pressure on OEMs in terms of logistics of handling and transporting large wind components, securing critical raw material as well as scaling up necessary domestic production infrastructure to meet the demand. There is increased interest in building lightweight, more efficient, and high-power dense drivetrains that will ease the burden on installation, minimize the raw material demand, increasing domestic sourceability. Despite good efficiency and reliability, existing drivetrain technologies such as direct-drive permanent magnet generators are heavy (> 300 tons), expensive, and often rely on large quantities of rare-earth permanent magnets (PMs), steel and copper.

17 WIND ENERGY↗

Outcomes of the DOE Workshop on Atmospheric Challenges for the Wind Energy Industry

The U.S. Department of Energy-funded Mesoscale-to-Microscale Coupling (MMC) project team planned and conducted a virtual Workshop on Atmospheric Challenges for the Wind Energy Industry on October 19 and 20, 2020. The goal of the workshop was to forge a dialog with the community, including industry representatives, on how modeling tools are currently being used, the present active atmospheric modeling research in support of wind energy, and required advancements in capabilities and technology to continue to advance wind energy deployment. The workshop was planned in collaboration with an industry advisory panel that included representatives from wind power plant developers, turbine manufacturers, and companies that provide resource assessment and forecasting services. The format of the workshop included panels from government research sponsors, visionaries from industry, and mixed panels of researchers discussing research status and needs. A shared keynote presentation from the Technical University of Denmark experts anchored the second day of the workshop. An emphasis was placed on understanding the research needs in the offshore environment. In addition, breakout opportunities were provided each day. On the first day, the breakout discussions addressed predesigned questions configured to elicit participants’ thoughts on needed research directions. The second-day breakouts treated three important technical topics through a combination of presentations and group conversations. Each workshop participant chose their breakout preference from among downscaling details, modeling for turbines, and using artificial intelligence for atmospheric modeling. The discussions were robust and productive. The outcomes of the workshop include archiving a series of recommendations from industry and the research community on research directions required to further advance wind energy deployment. Discussions confirmed the need for high-fidelity modeling but that there are specific areas of applicability and other areas where the time and cost of computation is prohibitive. In those cases, the high-fidelity models can inform low-order models that are more practical for real-time or widely deployed applications. Industry must consider the financial cost of performing more expensive modeling approaches, but industry engineers and researchers are using these approaches where there appears to be a return on investment. An emerging type of low-order model is based on machine learning (ML). Participants confirmed that there are many atmospheric phenomena that need to be modeled better, including low-level jets, cold air outbreaks, land-sea induced circulations, diurnal variability, thin stable boundary layers, dynamic changes such as from frontal passage, interaction of wakes and blockage, and more. For the offshore environment, there is wide agreement that some level of ocean-wave-atmospheric coupling is necessary to capture variations in rotor-level winds needed to plan and operate offshore wind plants. Another recurring recommendation is that more observations are needed, particularly for the offshore environment. Those observations should consider the needs for model improvement, both for physically based models and for ML models. Observations must capture atmospheric profiles of variables that are important to understanding and modeling atmospheric and oceanic phenomena that impact boundary layer winds. Models must be validated with data and the uncertainty quantified, particularly those that are sensitive to initial and boundary conditions. Finally, a repeated request was to consider the holistic needs of hybrid plants of wind, solar, and storage resources because those types of plants are likely to be the wave of the future. In addition, industry wishes to understand impacts of the resource under a changing climate for long-term planning.

17 WIND ENERGY↗

Optimal Hairpin Winding Configuration for EV Traction Motors to Enhance Active CMV Cancellation Capability of NPL.X Inverter

Active common-mode voltage (CMV) cancellation in neutral-point-less (NPL.X) inverter is an effective approach for reducing common-mode electromagnetic interference and alleviating voltage stress associated with high-speed switching in EV traction drives. However, the existing hairpin winding configuration often exhibits impedance imbalance due to slot leakage inductance and manufacturing constraints, limiting the effectiveness of active CMV cancellation. This paper investigates symmetric hairpin winding configurations for a dual-three-phase EV traction machine to improve impedance symmetry. Considering the manufacturing constraints of six-layer hairpin windings, four feasible symmetric winding configurations are analyzed. Two-dimensional finite-element analysis is performed to extract the impedance parameters of each configuration. The extracted impedance parameters are used to quantify the impedance mismatch between complementary phase pairs and evaluate its influence on active CMV cancellation. The results show that the fully interleaved winding configuration achieves perfectly balanced phase impedances with 0 % mismatch, whereas the mismatch in the other configurations ranges from approximately 2.4 % to 0.8 %. Consequently, the resulting total CMV overshoot is significantly suppressed to near zero voltage under high-voltage and high switching frequency operating conditions, demonstrating the importance of winding symmetry for maximizing the active CMV cancellation capability of the NPL.X inverter.

Lee, Kangbeen [Purdue Univ., West Lafayette, IN (U↗

U.S. Department of Energy Competitiveness Improvement Project (CIP) 2025 Prototype Manufacture Awardee: XFlow Energy

Vertical-axis wind turbines offer a compelling path to low-cost, reliable distributed energy that can compete with utility prices for businesses, landowners, and municipalities in rural areas. They generate power by using a main rotor shaft perpendicular to the ground to pick up wind from different directions without a yaw mechanism. However, previous commercialization attempts struggled to account for the unsteady aerodynamics of this design, leading to low power production and/or premature structural failure. To address these challenges, Competitiveness Improvement Project recipient XFlow Energy is building on work completed during three previous CIP funding awards to develop a 30-kW vertical-axis wind turbine that achieves both low costs and high energy output.

17 WIND ENERGY↗

Recent and future developments in pultrusion technology with consideration for curved geometries: A review

Herein this paper examined the current state and future developments in pultrusion with particular emphasis on its application in curved part manufacturing. The relationship between factors such as resin chemistry, fiber characteristics, and die geometry that influences the properties of pultruded product were highlighted. Moreover, the specific challenges associated with pultruding curved parts such as the complexities in achieving uniformity and structural integrity in such geometries were discussed. The review emphasized mold design, process improvement, adaptive control systems for precise resin impregnation and material selection to address these challenges. Additionally, the paper suggests the integration of real-time monitoring and data analytics as ways to enhance quality control during curved parts pultrusion. These advancements will help to overcome challenges specific to curved pultrusion and make the process more efficient. Other manufacturing techniques such as filament winding, thermoforming, pulforming were mentioned as alternatives to curved parts pultrusion. The review also explores pultruded variable curvature processes, highlighting some notable patents and article related to this subject matter. Production of pultruded variable curvature parts was seen as a key driver that can shape the future of pultrusion. Finally, the paper anticipates future trends, with sustainability, customization, integration of advanced materials, and development of techniques for pultrusion of composites parts.

42 ENGINEERING↗

Fermilab Automation of Coil Winding System

The automated coil winder project creates a repeatable, scalable method for producing superconducting magnet coils with increased accuracy and efficiency. The design uses an ortho cyclic winding method to achieve high fill factors by combining computer numerical control (CNC), microcontroller-based controls, and sophisticated optimization techniques. The method optimizes coil turns, core geometry, and current consumption by utilizing analytical models based on magnetic moment, Ohm’s law, and power constraints. For particle accelerator applications, prototype testing using a 3D-printed coil winder has shown enhanced winding repeatability, thermal management, and manufacturability.

Dzida, Rafal [Northern Illinois U.]↗

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview

The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future. The effort was divided into three areas: Flexible Systems Development (FSD), Mission Advanced Entry Concepts (AEC), and Flight Validation. FSD consists of a Flexible Thermal Protection Systems (FTPS) element, which is investigating high temperature materials, coatings, and additives for use in the bladder, insulator, and heat shield layers; and an Inflatable Structures (IS) element which includes manufacture and testing (laboratory and wind tunnel) of inflatable structures and their associated structural elements. AEC consists of the Mission Applications element developing concepts (including payload interfaces) for missions at multiple destinations for the purpose of demonstrating the benefits and need for the HIAD technology as well as the Next Generation Subsystems element. Ground test development has been pursued in parallel with the Flight Validation IRVE-3 flight test. A larger scale (6m diameter) HIAD inflatable structure was constructed and aerodynamically tested in the National Full-scale Aerodynamics Complex (NFAC) 40ft by 80ft test section along with a duplicate of the IRVE-3 3m article. Both the 6m and 3m articles were tested with instrumented aerodynamic covers which incorporated an array of pressure taps to capture surface pressure distribution to validate Computational Fluid Dynamics (CFD) model predictions of surface pressure distribution. The 3m article also had a duplicate IRVE-3 Thermal Protection System (TPS) to test in addition to testing with the Aerocover configuration. Both the Aerocovers and the TPS were populated with high contrast targets so that photogrammetric solutions of the loaded surface could be created. These solutions both refined the aerodynamic shape for CFD modeling and provided a deformed shape to validate structural Finite Element Analysis (FEA) models. Extensive aerothermal testing has been performed on the TPS candidates. This testing has been conducted in several facilities across the country. The majority of the testing has been conducted in the Boeing Large Core Arc Tunnel (LCAT). HIAD is continuing to mature testing methodology in this facility and is developing new test sample fixtures and control methodologies to improve understanding and quality of the environments to which the samples are subjected. Additional testing has been and continues to be performed in the NASA LaRC 8ft High Temperature Tunnel, where samples up to 2ft by 2ft are being tested over representative underlying structures incorporating construction features such as sewn seams and through-thickness quilting. With the successful completion to the IRVE-3 flight demonstration, mission planning efforts are ramping up on the development of the HIAD Earth Atmospheric Reenty Test (HEART) which will demonstrate a relevant scale vehicle in relevant environments via a large-scale aeroshell (approximately 8.5m) entering at orbital velocity (approximately 7km/sec) with an entry mass on the order of 4MT. Also, the Build to Print (BTP) hardware built as a risk mitigation for the IRVE-3 project to have a "spare" ready to go in the event of a launch vehicle delivery failure is now available for an additional sub-orbital flight experiment. Mission planning is underway to define a mission that can utilize this existing hardware and help the HIAD project further mature this technology.

Hughes, Stephen J.↗

Comparison of Multiscale Method of Cells-Based Models for Predicting Elastic Properties of Filament Wound C/C-SiC

Three different multiscale models, based on the method of cells (generalized and high fidelity) micromechanics models were developed and used to predict the elastic properties of C/C-SiC composites. In particular, the following multiscale modeling strategies were employed: Concurrent multiscale modeling of all phases using the generalized method of cells, synergistic (two-way coupling in space) multiscale modeling with the generalized method of cells, and hierarchical (one-way coupling in space) multiscale modeling with the high fidelity generalized method of cells. The three models are validated against data from a hierarchical multiscale finite element model in the literature for a repeating unit cell of C/C-SiC. Furthermore, the multiscale models are used in conjunction with classical lamination theory to predict the stiffness of C/C-SiC plates manufactured via a wet filament winding and liquid silicon infiltration process recently developed by the German Aerospace Institute.

multiscale modeling↗

Test of a trail cryogenic balance in the ONERA T2 wind tunnel

The three component cryogenic balance designed and manufactured by the ONERA Large Means Directorate, was equipped with a light alloy schematic model and tested at the end of 1984 at the T2 wind tunnel in gusts at low temperatures up to 120 K. The tests pertained to the impact of the cryogenic conditions on the behavior of extensometric bridges while cooling the balance-model system mounted in the conditioning device and during gusts with models in the test section. A few tests with thermal disequilibrium between the flow and balance made it possible to confirm the proper operation in the range 120 to 300 K. This gust system showed that the balance, which was well compensated thermally, may be used in T2 with and without precooling. For any thermal gradient, the analysis was always performed with the same matrices and aerodynamic coefficients were obtained with the same precision.

Blanchard, A.↗