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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2025

SCILLA 1 Hz merged data

The overarching goal of the Southern California Interactions of Low Cloud and Land Aerosol (SCILLA) experiment is to understand the interplay among horizontal circulation, vertical mixing, aerosols and clouds in the Southern California (SoCal) Bight. Eddy circulations within the Bight are frequently present when low clouds are persistent, and the transport of pollution into the Bight also depends on the regional and local circulation. The contrast between the cooler near-surface marine air with the warmer overlying continental and/or free tropospheric air is crucial to the efficiency of vertical mixing, and vertical transport of aerosols into the boundary layer. The CIRPAS Twin Otter aircraft was based in San Diego, CA, to perform airborne measurements of winds, aerosols, and clouds for 1 month (June 2023), with a geographical focus on the SoCal Bight. The deployment coincided with the DOE-funded Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE), which deployed a range of ground-based aerosol and cloud sensors and samplers from Feb. 2023 to Feb. 2024, mostly in and around San Diego. The aircraft deployment specifically seeks to answer questions about the cause of regions of elevated cloud drop number concentration from satellite-observed variations over the SoCal Bight, the role of horizontal advection relative to vertical transport and mixing, and the role of the thermodynamic properties (rather than aerosol properties) of continental air in modifying nearshore clouds.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Regional-scale, sector-specific evaluation of global CO2 inversion models using aircraft data from the ACT-America project

We use vertical profiles of airborne measurements of CO2 from frontal cases during the summer 2016 Atmospheric Carbon and Transport – America (ACT-America) campaign to evaluate the skill of a set of ten global CO2 inversion models participating in the Orbiting Carbon Observatory – 2 (OCO-2) Model Intercomparison Project (MIP). Model errors and biases (model minus observation) were categorized by region (Mid-Atlantic, Midwest, and South), frontal sector (warm or cold), and transport model (predominantly Tracer Model 5 (TM5) and Goddard Earth Observing System – Chemistry (GEOS-Chem)). Overall, the inversions reproduce the general structures of the observed vertical profiles and the enhanced / depleted low-level CO2 in warm / cold sectors, but tend to underestimate the magnitude of the sector difference in each region. In the Midwest and South warm sectors, inversion biases were about 1 ppm above 1500 m AGL, though model spread (quantified by interquartile range) was often even smaller; below 1500 m AGL, model biases were negative and about -2 ppm near the surface. For the Midwest and South cold sectors, models had +2-3 ppm biases below 1500 m AGL, but with comparable model spread. Uniquely, in the Mid-Atlantic there was a consistent difference between TM5 and GEOS-Chem mole fractions for both sectors up to 3000 m AGL (TM5 lower by 2 ppm), on the order of the observation-relative biases. In the MidAtlantic TM5 inversions had negative biases in warm sectors, while GEOS-Chem inversions had positive biases in cold sectors. Possible reasons for the regional variability are discussed.

Gaudet, Brian J.↗
DOE OSTI2022

Energy Impacts of Electric Aircraft: An Overview

Commercial aviation represents approximately 2% of the global emissions of greenhouse gases, yet presently relies exclusively on fossil fuels as a source of energy. This paper evaluates to what extent an all-electric aircraft can provide an alternative. First, three classes of aircraft are modeled at various timelines in the future: 50/100/150 passenger capacity in 2030/2040/2050. Technology is assumed to improve over time, especially with regards to battery specific energy, resulting in aircraft with increased range. A database of all domestic flights in the US in 2019 is then used to filter and aggregate flights suited for replacement by electric aircraft. In the short term (2030), no viable aircraft can meet the requirements of each class. By 2040, a third of the flights can be done by an all-electric aircraft, but only short ones, as the range does not exceed 500 mi, resulting in 3% of total passenger-miles. By 2050, owing to the most optimistic technology assumptions, a quarter of all passenger-miles can be flown by electric airplanes. The resulting displaced jet fuel is also calculated.

Aviation sustainability↗
DOE OSTI2021

H2@Airports (Workshop Summary Report)

This report serves as the proceedings of the H2@Airports Workshop held virtually by the U.S. Department of Energy (DOE) in collaboration with the U.S. Department of Transportation (DOT) and Department of Defense (DOD), November 4-6, 2020. Presentations from the workshop can be found at H2@Airports Workshop: https://www.energy.gov/eere/fuelcells/h2airports-workshop. The workshop was held to assess the state of the art for electric aircraft and airport applications specifically using hydrogen fuel cells, to discuss operational requirements and lessons learned on early fuel cell aviation and airport projects, to understand current technology gaps, to identify collaborative research and development (R&D) opportunities, to highlight codes, standards, safety, and regulatory challenges, and to identify potential actions that address them. Experts and stakeholders from industry, government, and academia met to discuss the current state of the art of hydrogen and fuel cell technologies and the requirements for using these technologies in aviation applications and land-based applications at airports. This report summarizes the discussions and diverse opinions expressed at the workshop.

08 HYDROGEN↗
DOE OSTI2022

High concentrations of ice: Investigations using polarimetric radar observations combined with in situ measurements and cloud modeling (Final Report)

This DOE-funded joint project had the over-arching goal of understanding the reasons for observed size distributions of ice particles in cold clouds. Its approach involves the use of cloud models and field observations by radar and aircraft of real storms. The project addresses three major research objectives: (1) Utilize a novel polarimetric radar technique to retrieve size distributions and amounts of ice from radar data collected during the previous DOE ARM field campaigns; (2) Evaluate the results of ice microphysical retrievals using available in situ aircraft measurements and other remote sensors (e.g., vertically pointing cloud radars and wind profilers); (3) Improve the treatment of microphysical processes leading to cloud glaciation and ice multiplication in numerical cloud models. The study was performed by three research organizations: University of Oklahoma, The Hebrew University of Jerusalem, Israel, and Lund University, Sweden. The Israel and Swedish partners were funded by the sub-awards from the University of Oklahoma. Cloud modeling studies have been performed by the research teams at The Hebrew University of Jerusalem (HUJ) and Lund University to identify the origins of high concentrations of cloud ice in areas of high ice water content (HIWC). The Hebrew University Cloud Model (HUCM) with full spectral bin microphysics and the Lund University aerosol-cloud (AC) model with a hybrid bin / bulk microphysics scheme complementing HUCM were utilized for simulations. Both research teams had particular focus on secondary ice production (SIP) as one of the possible sources of enhanced ice concentration. The HUJ group suggested a novel concept of ice multiplication during droplet freezing. It is assumed that splintering and droplet fragmentation during droplet freezing takes place because of dendritic growth within a supercooled drop. The resulting simulations of SIP generated small ice in concentrations exceeding hundreds per liter similar to what was observed in the HIWC regions of the tropical storms. The Lund team explored the SIP mechanisms such as breakup of ice particles due to ice-ice collisions and ice sublimation that are expected to dominate the continental storms. They also quantified the impact of homogeneous nucleation of cloud droplets on the total number concentration of ice at very low temperatures near the tops of the clouds. Additionally, the Lund AC model is able to simulate the effect of aerosols of various types (including biological) on the cloud life cycle and the corresponding ice production. The HUCM / AC model was used to simulate one of the “golden” cases of the DOE MC3E campaign on 20 May 2011. The model output was converted into the fields of polarimetric radar variables using the polarimetric radar forward operator developed at the University of Oklahoma and compared with radar observations and in situ microphysical measurements onboard research aircraft. It was demonstrated that specific differential phase KDP is the best radar parameter to identify the HIWC areas and quantify the corresponding ice parameters. For the first time, the shape of the vertical profile of KDP was realistically reproduced by the cloud model with the KDP maximum in the dendritic growth layer (DGL) centered at the -15°C isotherm. The University of Oklahoma team has developed a methodology for polarimetric radar retrievals of such microphysical parameters of ice as ice water content (IWC), mean volume diameter (Dm), and total number concentration (Nt) of ice particles. These retrievals have been validated using in situ aircraft measurements during 6 field campaigns and proved to be quite robust and reliable. This allowed to build the first climatology of the vertical profiles of polarimetric radar variables and retrieved microphysical parameters for the three types of weather systems: continental MCSs, maritime MCSs, and tropical cyclones / hurricanes (Hu and Ryzhkov 2022). The data were collected by a multitude of the WSR-88D radars in 13 continental and 10 maritime MCSs and 11 landfalling hurricanes. The HIWC areas were identified within the examined storms and the corresponding “HIWC statistics” was compared with the “background” one without HIWC. An overarching conclusion of the study is that maritime tropical storms (MCSs and hurricanes) are characterized by smaller size ice in higher concentration compared to the continental MCSs. High ice water content in the HIWC areas is primarily caused by a strong jump in a number concentration of ice particles rather than the increase of their size compared to the “background” environment. This may point to the homogeneous nucleation of excessive amounts of supercooled droplets and / or secondary ice production as the possible origins of HIWC. Such a climatology provides a good observational reference for the modelers to evaluate the performance of their models. As an example, the in-depth analysis of the 20 May 2011 MC3E case shows that the advanced cloud models developed in the course of this study still tend to underestimate the number concentration of ice in the HIWC areas although they succeed in reproducing realistically looking vertical profiles of IWC and Nt. The results of the project research are summarized in 13 journal papers.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Evaluating Entrainment–Mixing Characteristics through Direct Comparisons of Drop Size Distributions Using In Situ Observations from ACE-ENA

Abstract Constraining the impacts of entrainment and associated mixing (i.e., entrainment–mixing) on cloud properties continues to be difficult, partly due to observational uncertainties as well as a lacking consensus of which methodologies for diagnosing entrainment–mixing are most appropriate. This study introduces a novel method to evaluate the presence and degree of inhomogeneous and homogeneous mixing using ∼100 h of in situ observations from a research aircraft over the northeastern Atlantic. Specifically, drop size distributions are compared between regions containing negligible and significant entrainment for select flight legs, making a direct characterization of the degree of homogeneous and inhomogeneous mixing possible. A measure of drop concentration variance is used as a proxy variable to diagnose entrainment–mixing. Results correspond well with entrainment–mixing metrics, showing lower Damköhler numbers where drop size distributions shift toward smaller drop sizes (i.e., inhomogeneous mixing) and greater transition length scales where drop size distributions do not (i.e., homogeneous mixing). Inhomogeneous mixing occurs in most samples from Aerosol and Cloud Experiment in the Eastern North Atlantic (ACE-ENA) (regardless of homogeneous mixing frequencies increasing with increasing spatial resolution from ∼100 to ∼10 m) and is associated with decreased drop size relative dispersion and both greater aerosol and drop concentrations compared with homogeneous mixing. Precipitating clouds have a greater frequency of homogeneous mixing compared with nonprecipitating clouds. The proposed methodology is similarly applied to in situ observations of southeast Pacific stratocumulus, shallow convective clouds over central Oklahoma and low-level clouds over the Southern Ocean. All four locations are primarily dominated by inhomogeneous mixing with minimal variability among each region.

Clouds↗
DOE OSTI2021

Designing the Insulation System for Motors in Electrified Aircraft: Optimization, Partial Discharge Issues and Use of Advanced Materials

Designing the insulation system for motors to be used in electrical aircraft requires efforts for maximizing specific power, but, in parallel, particular attention to achieve high reliability. As a major harm for organic insulation systems is partial discharges, design must be able to infer their likelihood during any operation stage and handle their potential inception. This paper proposes a new approach to carry out optimized or conservative insulation system designs which can provide the specified life at the chosen failure probability as well as look at the option of possibly reducing the risk of partial discharges to zero, at any altitude. Examples of designing turn, phase to ground and phase-to-phase insulation systems are reported, with cases where the design can be optimized and other cases where the optimized design does not pass IEC testing standard. Therefore, the limits for design feasibility as a function of the required level of safety and reliability are discussed, showing that the presence of partial discharges cannot be always avoided even through conservative design criteria. Therefore, the use of advanced, corona-resistant materials must be considered, in order to reach a higher, sometimes redundant, level of reliability.

Ramin, Robin (ORCID:0000000211455006)↗
DOE OSTI2024

A Compact, Single Stage, >1 kV Medium-Voltage Line Impedance Stabilization Network

This paper presents the design of a single-phase, single-stage line impedance stabilization network (LISN) for medium-voltage (MV) applications. More than 1 kV rated widebandgap (WBG) power semiconductor switches are increasingly utilized in new, emerging power electronics energy systems to improve power density and efficiency. However, due to inherently fast-switching speeds, WBG switch modules emit considerable electromagnetic interference (EMI) (e.g., common mode (CM) or differential mode (DM)). State-of-the-art offers standardized LISN solutions to validate and certify the new energy system for electromagnetic compatibility (EMC). However, most are for low voltage applications (i.e., < 1 kV). MV LISNs (i.e., > 1 kV) are rare until recently and literature does not provide sufficient guidelines for designing and characterizing such devices. It has been a critical challenge for many scientists and engineers to reliably certify the emerging MV energy systems (e.g., electric ships and aircraft). This paper addresses such a technology gap. Specifically, a CISPR 16-1-2 compliant 50Ω/50μH LISN with 1.5kV, 75A and 30MHz measurement capability has been proposed. Detailed performance study versus non-linear parasitic parameters variations in MV inductors and capacitors have been done. Based on new understandings, novel techniques to intuitively mitigate unwanted parasitic have been proposed to develop the proposed LISN successfully. Thorough characterization of important LISN parameters are presented and factors influencing them are analyzed. A rigorous analysis, experimental tests, and in-depth comparisons over state-of-the-art have been made to validate the effectiveness. This is done through the state-of-the-art 300kVA MV EMI testbed.

42 ENGINEERING↗
DOE OSTI2024

Autonomous Emergency Landing for Fixed-Wing Aircraft with Energy-Constrained Closed-Loop Prediction

Here this paper presents a new approach for autonomous motion planning for aircraft suffering from a loss-of-thrust emergency. Specifically, we show how modifications to the Closed-Loop Rapidly exploring Random Trees (CL-RRT) framework combined with controlled energy dissipation can enable rapid and effective kinodynamic motion planning. This CL-RRT Glide algorithm uses closed-loop prediction not only for node connections but also to estimate the remaining energy and prune infeasible paths. This greatly speeds up the search process, which is essential for emergency situations. In addition, we improve the ability of the gliding aircraft to reach a goal position and energy state. We do so by creating a Dissipative Total Energy Control Scheme (TECS). Dissipative TECS enables the glider to lose excess altitude in order to reach a desired energy level. Simulation results illustrate how the proposed methods enable faster motion planning. We also integrate the system into a small unmanned aerial vehicle system and experimentally demonstrate autonomous glide planning and execution during a motor-failure event. This type of algorithm can primarily benefit unmanned aircraft but can also serve to assist pilots in stressful emergency situations.

42 ENGINEERING↗
DOE OSTI2022

5.1.6 Demo #6: NanoStitch (NAWAStitch) Multifunctional Composites Trade Validation

The overall objective of the NanoStitch Multifunctional Composites Trade Validation Demonstration project was to determine the value proposition of adding NanoStitch to rapid-cure composite systems for structures used in the expanding sector of advanced air mobility (AAM) and specifically electric vertical take-off and landing (eVTOL) aircraft. The expected value proposition was stronger composite parts, with new multifunctional attributes, that are lower cost to fabricate and maintain. NanoStitch is a new composite innovation where a contiguous vertically aligned carbon nanotube (VACNT) forest is located between each ply of a laminate composite resulting in improved mechanical properties as well as other multifunctional properties such as enhanced thermal and electrical conductivity. NanoStitch was originally distributed by N12, later acquired by NAWA Technologies, now called NAWAStitch, and henceforth referred to in this document as NAWAStitch. Two significant evaluations were framed to help meet the overall objective. First, was Task 1 to evaluate the effects that adding NAWAStitch to a rapid cure material system would have on the mechanical and processing properties of the material. Second, was Task 2 to evaluate the workability of adding NAWAStitch to practical flight demonstration articles. From previous research, it was already known that the application of NAWAStitch to a composite structure can enhance the mechanical properties of that structure. However, this project will help the engineering community understand those benefits and the basic structural strength values to apply when incorporating NAWAStitch material into composite structure that utilizes a rapid-cure resin system, which is novel. Testing showed that by adding NAWAStitch to the prepreg, most material properties were improved because the VACNTs strengthened the resin to fiber interface, and the interface itself, between plies. For example compression strength improved by more than 20%, and erosion resistance by more than 50%. The UDRI team identified two flight demonstration articles through discussions with Aurora Flight Sciences (Aurora) and reviewing literature on air mobility and the eVTOL market. The demonstration articles were a thin skin honeycomb panel and a section from an eVTOL propeller blade. The manufacturing and testing trials of the demonstration articles were as follows: • NAWAStitch added no manufacturing complexity or detriment to the article physical qualities, while at the same time added multifunctional properties such as enhanced rain erosion and electrothermal de-icing besides enhanced mechanical properties • VACNTs did not increase or hurt the mechanical properties of the interface between honeycomb core materials and the thin skin face sheet • Demonstrated successful de-icing function in an eVTOL propeller meeting real-world specifications in uniformity and endurance • Multifunctional eVTOL propeller cost analysis showed a cost savings of at least 67 % for a single propeller blade with multifunctional de-icing capability and improved mechanical properties which equates to a potential savings of $10,116 per eVTOL aircraft with six three-bladed propellers Overall, the results of this project can provide additional tools for the composite industry to optimize energy efficiency through faster and stronger composite parts that are lower cost to fabricate and maintain. Additionally, the results of this effort can help US industry like NAWA America set the stage for rapid growth and establishment of a manufacturing facility in Ohio. The project has given NAWA America the basic understanding of how the addition of VACNTs to a composite structure can affect the mechanical properties and hence point them to potential commercial applications. The project has also provided Teijin Carbon US with another potential material application for their rapid cure materials that are manufactured at the Renegade facility in Miamisburg, OH.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Aircraft-Integrated Meteorological Measurement System (AIMMS) Instrument Handbook

The AIMMS-20 probe is manufactured by Aventech Research Inc. and measures platform position, velocity, attitude, ambient temperature, static pressure, and the differential pressures from a 5-port hemispheric gust probe, and combines all these measured data into a calculation of the ambient winds. A detailed description of the AIMMS-20 specifications is available here. Note: The Aventech engineers use the aircraft-centric frame of reference common to aeronautical engineering, which defines z as down.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Integrating Characteristic Arctic Vegetation in a Land Surface Model Improves Representation of Carbon Dynamics Across a Tundra Landscape

Arctic warming is altering vegetation and carbon dynamics with global implications, yet Earth System Model (ESM) predictions in the Arctic remain highly uncertain, in part due to historically limited data for model parameterization and validation. As such, ESMs typically represent Arctic ecosystems in an oversimplified manner. Recently, nine plant functional types (PFTs) designed to realistically represent tundra vegetation were integrated into the Energy Exascale Earth System Model (E3SM) Land Model (ELM) and parameterized using plot-scale observations from a single site. Additional evaluation was needed to determine their transferability across the Arctic. Here, in this study, we evaluated whether refined representation of tundra vegetation improved model accuracy by conducting spatially explicit 100 × 100 m resolution ELM simulations on Alaska's Seward Peninsula. Simulations with the default two-PFT configuration and with the nine Arctic-specific PFTs were benchmarked against observations of net ecosystem exchange, gross primary production, and aboveground biomass from multiple data streams including an eddy covariance flux tower, flux chambers, and aircraft and unoccupied aerial system hyperspectral remote sensing. Evaluation revealed that Arctic-specific PFT simulations produced more realistic landscape-level carbon exchanges, and better captured observed heterogeneity in biomass and productivity, explaining 60%–70% of spatial variance (R 2 = 0.6–0.7) compared to just 12%–18% (R 2 = 0.12–0.18) with the default configuration. However, the refined model failed to reproduce observed aboveground biomass for highly productive alder-willow communities, requiring further evaluation of carbon allocation parameterizations for tall shrubs that are increasingly expanding across tundra landscapes. Our results demonstrate that enhanced representation of vegetation heterogeneity boosts predictive understanding of tundra carbon dynamics, facilitating regional to pan-Arctic model and remote-sensing scaling.

Murphy, Bailey A. [Oak Ridge National Laboratory (↗
DOE OSTI2022

Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes: Preprint

This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

additive manufacturing↗
DOE OSTI2024

Measuring the robustness of predictive probability for early stopping in two-group comparisons

We report physical experiments are often expensive and time-consuming. Test engineers must certify the compatibility of aircraft and their weapon systems before they can be deployed in the field, but the testing required is time consuming, expensive, and resource limited. Adopting Bayesian adaptive designs is a promising way to borrow from the successes seen in the clinical trials domain. The use of predictive probability (PP) to stop testing early and make faster decisions is particularly appealing given the aforementioned constraints. Given the high-consequence nature of the tests performed in the national security space, a strong understanding of new methods is required before being deployed. Although PP has been thoroughly studied for binary data, there is less work with continuous data, where many reliability studies are interested in certifying the specification limits of components. A simulation study evaluating the robustness of this approach indicates early stopping based on PP is reasonably robust to minor assumption violations, especially when only a few interim analyses are conducted. The simulation study also compares PP to conditional power, showing its relative strengths and weaknesses. A post-hoc analysis exploring whether release requirements of a weapon system from an aircraft are within specification with desired reliability resulted in stopping the experiment early and saving 33% of the experimental runs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

An analysis of parameters affecting ampacity in aircraft bipolar MVDC power cables via coupled electrical, thermal, and computational fluid dynamic modelling

Abstract The next generation of aircraft, including more electric aircraft and all‐electric aircraft (AEA), requires electric power systems with high power density and low system mass specifications. Increasing the voltage of the system to the range of a few kV, medium voltage (MV), is a reasonable approach to achieving high‐power‐density and low‐system‐mass EPSs for aircraft applications. Higher voltages, however, pose many challenges for aviation MV power cables such as arcs and arc tracking, partial discharges (PDs), and thermal management. In this regard, thermal management is more challenging since heat transfer by convection is greatly reduced at wide‐body aircraft's cruising altitudes due to the reduced air pressure. In this paper, a finite element method (FEM) model is developed in COMSOL Multiphysics for an aircraft bipolar MVDC (±5 kV) power cable. Using the model, the maximum permissible cable current at a low pressure of 18.8 kPa (at an altitude of 12.2 km from sea level, the usual cruising altitude for wide‐body aircraft) is calculated. Also, an analytical model is developed based on analytical and proven empirical correlations governing conductive, radiative, and convective heat transfers at the steady state to estimate the ampacity of the bipolar cable system at reduced pressure. It was shown that the proposed analytical model can be used for atmospheric pressure and systems with a larger number of poles, expanding its range of applications. The results of the FEM and analytical models correlate at wide ranges of parameters such as ambient temperature, duct size, distance between the positive and negative pole cables, and the overall diameter of the cables. The influence of horizontal and vertical arrangement of poles is included in the analytical model. The results of this study can be used to design bipolar MVDC power cable systems for the envisaged wide‐body AEA.

Azizi, Arian↗
DOE OSTI2024

Data Based Shock Test Specification

It is vital that avionic packages used for testing and certifying the reliability and safety of U.S. nuclear weapons with platform aircraft survive exposure to shock environments during transportation and delivery. The objective of this research was to characterize the response to these transportation shock environments delivering accurate shock test specifications in order to set laboratory programming material and device certification rigor. Responses to shock events were analyzed in the frequency domain via the Shock Response Spectrum (SRS). Shocks were then grouped based on respective behavior of maximum response accelerations which were pseudorandomly resampled and compared to test data to form test specifications based on the MinerPalmgren hypothesis. In addition to discovering significant over testing in current shock specifications, a new systematic, data-driven approach to designing shock specifications was formulated.

42 ENGINEERING↗