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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 OSTI2023

Reman Co-Design: A Combined Design and Remanufacturing Optimization Framework for the Sustainable Design of High-Value Components

Remanufacturing is a process that returns end-of-life equipment to as-new conditions and offers numerous environmental and economic benefits. To fully capitalize on remanufacturing, its synergistic interactions with design must be fully realized and addressed during the design stage. Although this fact is widely recognized in the literature, most of the current studies focus primarily either on the design or remanufacturing aspects of design for remanufacturing (DfRem). In an effort to offer a more integrated DfRem approach than those reported in the literature, we propose a new combined design and remanufacturing optimization (reman co-design) framework that takes a holistic approach by leveraging the intricate interplay between design and remanufacturing. Here, the aim of this formulation is to identify the optimal decisions that maximize the benefits of remanufacturing throughout the entire lifespan of a product. To showcase the utility of the new formulation, we are using a case study of a hydraulic manifold, (re)manufactured by John Deere. Using this industry example, we compare the results of reman co-design to the ones from a decoupled remanufacturing design approach. Results reveal that remanufacturing benefits are better realized and improved upon when using the developed reman co-design approach.

design for X↗
DOE OSTI2022

Impact of Timing in the Design Process on Students’ Application of Design for Additive Manufacturing Heuristics

The goal of this work is to study the way student designers use design for additive manufacturing (DfAM) rules or heuristics. It can be challenging for novice designers to create successful designs for additive manufacturing (AM), due to its recent surge in popularity and lack of formal education or training. A study was carried out to investigate the way novices apply DfAM heuristics when they receive them at different points in the design process. A design problem was presented to students, and three different groups of student participants were given a lecture on DfAM heuristics at three different points in the design process: before the initial design, between the initial design and redesign, and after the redesign. The novelty and quality of each of the resulting designs were evaluated. Results indicate that although the DfAM heuristics lecture had no impact on the overall quality of the designs generated, participants who were given the heuristics lecture after the initial design session produced designs that were better-suited for 3D printing in the second phase of the design activity. However, receiving this additional information appears to prevent students from creatively iterating upon their initial designs, as participants who received heuristic information between the design sessions experienced a decrease in novelty between the two sessions. Additionally, receiving the heuristics lecture increased all students’ perceptions of their ability to perform DfAM-related tasks. Furthermore, these results validate the practicality of design heuristics in lecture form as AM training tools while also emphasizing the importance of iteration in the design process.

computer-aided design↗
DOE OSTI2025

From TPL assessment to design optimization: Wave energy converter control co-design applied to the RM3

The Reference Model (RM) project developed six marine energy converter concepts using a sequential design methodology, which, while widely adopted in the industry, often overlooks interactions between system components, resulting in suboptimal designs. One such example is the Reference Model 3 (RM3), a two-body point absorber wave energy converter (WEC). An assessment using the Technology Performance Level (TPL) revealed that RM3’s low power-to-cost ratio, partly due to expensive steel construction, limits its techno-economic performance. Here, this study aims to redesign RM3 by reducing its scale and employing control co-design to integrate WEC and Power Take-Off (PTO) dynamics, constraints, and cost considerations within an optimization framework. We demonstrate the limitations of RM3’s current PTO design and explore the benefits of scaling down to enhance techno-economic viability by lowering material costs. Using WecOptTool, we conduct a parameter sweep over gear ratios and spring stiffnesses for various Commercial Off-The-Shelf generators in irregular wave conditions. Our findings emphasize the importance of aligning PTO components with WEC dynamics, showing that control co-design and strategic scaling can improve RM3’s power-to-cost ratio. This study presents a transferable example of applied control co-design for other WECs, supporting early-stage developers in their design decisions.

Off the shelf components↗
DOE OSTI2017

Preconceptual design of a fluoride high temperature salt-cooled engineering demonstration reactor: Core design and safety analysis

Engineering demonstration reactors are nuclear reactors built to establish proof of concept for technology options that have never been built. Examples of engineering demonstration reactors include Peach Bottom 1 for high temperature gas-cooled reactors (HTGRs) and Experimental Breeder Reactor II (EBR-II) for sodium-cooled fast reactors. Engineering demonstrations have historically played a vital role in advancing the technology readiness level of reactor technologies. This paper details a preconceptual design for a fluoride salt-cooled engineering demonstration reactor. The fluoride salt-cooled high-temperature reactor (FHR) demonstration reactor (DR) is a concept for a salt-cooled reactor with 100 megawatts of thermal output (MWt). It would use tristructural-isotropic (TRISO) particle fuel within prismatic graphite blocks. FLiBe (2 7LiF-BeF2) is the reference primary coolant. The FHR DR is designed to be small, simple, and affordable. Core design characteristics, fuel cycle performance, and safety analysis of the FHR DR preconcept have been evaluated. The FHR DR core design features a negative or negligible void coefficient throughout a reactor operating cycle. Both single-batch (cartridge) and multiple-batch fuel cycles can be demonstrated in the FHR DR. The single-batch cycle length of the FHR DR core is estimated at between 12-18 months, assuming the successful qualification of composite carbon (C/C) or silicon carbide (SiC/SiC) structural fuel block tie rod material. Fuel cycle performance of the FHR DR is similar to a high temperature gas-cooled reactor. Preliminary safety analysis of the FHR DR indicates that the reactor could be used to demonstrate the inherent safety characteristics of FHR designs.

Brown, Nicholas R.↗
DOE OSTI2020

150-kW Three-Port Custom-Core Transformer Design Methodology

The design of a 150-kW high-frequency three-port transformer (TPT) for a triple active bridge (TAB) converter application is the focus of this paper. A non-tradeoff inclusive design methodology for custom-core transformers is proposed. Classic transformer design methodologies based on complex trade-offs mechanisms require significant effort to adjust the design for commercially available pre-sized cores. The proposed design is based on the development of a set of design equations that allows to select the core dimensions and the turns numbers for the windings that best accomplish the transformer specifications. Experimental evidence verifying the proposed theoretical design methodology is presented in this work.

Christian, Shamar↗
DOE OSTI2018

Design Load Analysis for Wave Energy Converters: Preprint

This study demonstrates a systematic methodology for establishing the design loads of a wave energy converter (WEC). The proposed design load methodology incorporates existing design guidelines, where they exist, and follows a typical design progression; namely, advancing from many, quick, order-of-magnitude accurate, conceptual stage design computations to a few, computationally intensive, high-fidelity, design validation simulations. The goal of the study is to streamline and document this process based on quantitative evaluations of the design loads' accuracy at each design step and consideration for the computational efficiency of the entire design process. For the WEC, loads, and site conditions considered, this study demonstrates an efficient and accurate methodology of evaluating the design loads.

16 TIDAL AND WAVE POWER↗
DOE OSTI2018

Design Tool for Estimating Chemical Hydrogen Storage System Characteristics for Light-Duty Fuel Cell Vehicles

The U.S. Department of Energy (DOE) has developed a vehicle framework model to simulate fuel cell-based light-duty vehicle operation for various hydrogen storage systems. This transient model simulates the performance of the storage system, fuel cell, and vehicle for comparison to DOE’s Technical Targets using four drive cycles/profiles. Chemical hydrogen storage models have been developed for the Framework model for both exothermic and endothermic materials. Despite the utility of such models, they require that material researchers input system design specifications that cannot be easily estimated. To address this challenge, a design tool has been developed that allows researchers to directly enter kinetic and thermodynamic chemical hydrogen storage material properties into a simple sizing module that then estimates the systems parameters required to run the storage system model. Additionally, this design tool can be used as a standalone executable file to estimate the storage system mass and volume outside of the framework model and compare it to the DOE Technical Targets. These models will be explained and exercised with existing hydrogen storage materials.

hydrogen storage materials, Fuel Cell Vehicles, de↗
DOE OSTI2016

Simulated performance of the optical Thomson scattering diagnostic designed for the National Ignition Facility

An optical Thomson scattering diagnostic has been designed for the National Ignition Facility to characterize under-dense plasmas. We report on the design of the system and the expected performance for different target configurations. The diagnostic is designed to spatially and temporally resolve the Thomson scattered light from laser driven targets. The diagnostic will collect scattered light from a 50 × 50 × 200 μm volume. The optical design allows operation with different probe laser wavelengths. A deep-UV probe beam (λ{sub 0} = 210 nm) will be used to Thomson scatter from electron plasma densities of ∼5 × 10{sup 20} cm{sup −3} while a 3ω probe will be used for plasma densities of ∼1 × 10{sup 19} cm{sup −3}. The diagnostic package contains two spectrometers: the first to resolve Thomson scattering from ion acoustic wave fluctuations and the second to resolve scattering from electron plasma wave fluctuations. Expected signal levels relative to background will be presented for typical target configurations (hohlraums and a planar foil).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Wind Turbine Design Optimization for Hydrogen Production

To help meet the need for inexpensive green fuels, we are working on wind turbine design optimization specifically for hydrogen production. We have thus far achieved a 1.53% decrease in LCOH as compared to a turbine optimized for LCOE using the same code, design variables, and models. We accomplished this by optimizing some components of the wind turbine tower, rotor, and drivetrain design with hydrogen production and costs in the design loop.

hydrogen↗
DOE OSTI2018

Safeguards by Design in Nuclear Engineering Design Courses: Engaging Universities in Safeguards by Design

Engaging professionals across the breadth of the nuclear industry to educate them on international safeguards objectives and methodology is logistically challenging, especially in the United States, where individuals may not interact with the IAEA and are not as familiar with implementing international safeguards. However, incorporating international safeguards concepts into the mandatory curriculum of nuclear-related university degree programs around the world, complementary to nuclear safety and security concepts, could reach individuals who will go on to be professionals acting in a variety of roles across the nuclear industry (e.g., developing nuclear-related advanced technologies, designing or operating nuclear facilities, serving as State regulators). This would ultimately lead to more effective and efficient safeguards, including helping to move safeguards by design from a concept to a standard practice, as future designers, operators, and State regulators would be more familiar with international safeguards. This could also potentially address human resource challenges by creating a broader base of individuals knowledgeable about the IAEA mission from which to draw future inspectors and analysts. In order to implement this idea, the Y-12 National Security Complex in Oak Ridge, Tennessee, in conjunction with the Center for Nuclear Security Science & Policy Initiatives (a research institute associated with Texas A&M University), targeted nuclear engineering undergraduate students taking the mandatory design course at Texas A&M and the University of Tennessee. The project objective was to introduce safeguards by design concepts to individuals who are planning to work in a broad range of nuclear-related careers. The paper describes the project methodology, which included the project leads creating and presenting lectures on safeguards to the design class and mentoring teams working on design team projects that incorporated safeguards. The paper also identifies lessons learned while incorporating safeguards topics into nuclear engineering university degree programs.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

DCS - A high flux beamline for time resolved dynamic compression science – Design highlights

The Dynamic Compression Sector (DCS) beamline, a national user facility for time resolved dynamic compression science supported by the National Nuclear Security Administration (NNSA) of the Department of Energy (DOE), has recently completed construction and is being commissioned at Sector 35 of the Advanced Photon Source (APS) at Argonne National Laboratory (ANL). The beamline consists of a First Optics Enclosure (FOE) and four experimental enclosures. A Kirkpatrick–Baez focusing mirror system with 2.2 mrad incident angles in the FOE delivers pink beam to the experimental stations. A refocusing Kirkpatrick–Baez mirror system is situated in each of the two most downstream enclosures. Experiments can be conducted in either white, monochromatic, pink or monochromatic-reflected beam mode in any of the experimental stations by changing the position of two interlocked components in the FOE. The beamline Radiation Safety System (RSS) components have been designed to handle the continuous beam provided by two in-line revolver undulators with periods of 27 and 30 mm, at closed gap, 150 mA beam current, and passing through a power limiting aperture of 1.5 x 1.0 mm{sup 2}. A novel pink beam end station stop [1] is used to stop the continuous and focused pink beam which can achieve a peak heat flux of 105 kW/mm{sup 2}. A new millisecond shutter design [2] is used to deliver a quick pulse of beam to the sample, synchronized with the dynamic event, the microsecond shutter, and the storage ring clock.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Experimental and Computational Mechanistic Studies Guiding the Rational Design of Molecular Electrocatalysts for Production and Oxidation of Hydrogen

Understanding how to control the movement of protons and electrons is crucial to the design of fast, efficient electrocatalysts for hydrogen production and oxidation based on earth-abundant metals. Our work seeks to elucidate fundamental questions about proton movement. We have demonstrated that incorporating a pendant amine functioning as a proton relay in the second coordination sphere of a metal complex helps proton mobility, resulting in faster and more energy efficient catalysts. Proton transfer reactions are often rate limiting, and are influenced by several factors, such as pKa values, steric effects, hydrogen bonding, and solvation/desolvation of the exogenous base and acid employed. The presence of multiple protonation sites introduces branching points along the catalytic cycle, making less productive pathways accessible, or leading to the formation of stable off-cycle species. Using ligands with only one pendant amine mitigates this problem and results in catalysts with high rates for production of H2. For H2 oxidation catalysts, iron complexes with a high H2 binding affinity were developed. However, the improvement of H2 binding enthalpy resulted in a pKa mismatch between the protonated metal center and the protonated pendant amine, and consequently to rate-limiting intramolecular proton movement. Taken altogether, our results demonstrate the necessity of optimizing the entire catalytic cycle, as the optimization of a specific catalytic step can negatively influence another step, and not necessarily lead to better catalytic performance. We discuss a general procedure, based on thermodynamic arguments, which allows the simultaneous minimization of the free energy change of each catalytic step, yielding a nearly flat free energy surface, with no large barriers due to energy mismatches from either high- or low-energy intermediates. This research was supported as part of the Center for Molecular Electrocatalysis, an Energy Frontier Research Center funded by the U.S. Department of Energy, Office of Science, Office of Basic Energy Sciences. Pacific Northwest National Laboratory is operated by Battelle for DOE.

hydrogen, catalysis, quantum chemistry, proton tra↗