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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 OSTI2018

Material Stream Strategy for Lithium and Inorganics (U)

Design Agency Responsibilities: Manufacturing Support to meet Stockpile Stewardship goals for maintaining the nuclear stockpile through experimental and predictive modeling capability. Development and maintenance of Manufacturing Science expertise to assess material specifications and performance boundaries, and their relationship to processing parameters. Production Engineering Evaluations with competence in design requirements, material specifications, and manufacturing controls. Maintenance and enhancement of Aging Science expertise to support Stockpile Stewardship predictive science capability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Telemetry and H-Gear Engineering Hardware Design and Delivery Standards

Telemetry and H-Gear Engineering, Org. 8430, is frequently required to design, manufacture, test, and deliver products directly to flight tests and important ground tests. Due to schedule or budget constraints, these deliveries often cannot follow the full product acceptance process laid out in Sandia's Realize Product Processes. Telemetry and H-Gear Engineering therefore created tailored quality expectations and outputs for products that fall into this category. This document describes these quality requirements and the reasons they have been put in place.

42 ENGINEERING↗
DOE OSTI2018

Pressure core analysis of geomechanical and fluid flow properties of seals associated with gas hydrate-bearing reservoirs in the Krishna-Godavari Basin, offshore India

Physical properties of the sediment directly overlying a gas hydrate reservoir provide important controls on the effectiveness of depressurizing that reservoir to extract methane from gas hydrate as an energy resource. The permeability of overlying sediment determines if a gas hydrate reservoir’s upper contact will provide an effective seal that enables efficient reservoir depressurization. Compressibility, stiffness and strength indicate how overlying sediment will deform as the in situ stress changes during production, providing engineering data for well designs. Assessing these properties requires minimally-disturbed sediment. India’s National Gas Hydrates Program Expedition 2 (NGHP-02) provided an opportunity to study these seal sediment properties, reducing disturbance from gas exsolution and bubble growth by collecting a pressure core from the seal sediment just above the primary gas hydrate reservoir at Site NGHP-02-08 in Area C of the Krishna-Godavari Basin. The effective stress chamber (ESC) and the direct shear chamber (DSC) devices in the suite of Pressure Core Characterization Tools (PCCTs) were used to measure permeability, compressibility, stiffness and shear strength at the in situ vertical stress. Geotechnical properties of the predominantly fine-grained seal layer at in situ vertical stress are in typical clay sediment ranges, with low measured permeability (0.02 mD), high compressibility (C c = 0.26 – 0.33) and low shear strength (404 kPa). Though pressure and temperature were maintained throughout the collection and measurement process to stabilize gas hydrate, the lack of effective stress in the pressure core storage chamber and the chamber pressurization with methane-free water caused core expansion and gas hydrate in a thin coarser-grained layer to dissolve. The PCCTs can reapply in situ stress with incremental loading steps during a consolidation test to account for sediment compaction. Lastly, gas hydrate dissolution can be limited by storing cores just above freezing temperatures, and by using solid spacers to reduce the storage chamber’s free volume.

09 BIOMASS FUELS↗
DOE OSTI2019

Machine learning framework for assessment of microbial factory performance

Metabolic models can estimate intrinsic product yields for microbial factories, but such frameworks struggle to predict cell performance (including product titer or rate) under suboptimal metabolism and complex bioprocess conditions. On the other hand, machine learning, complementary to metabolic modeling necessitates large amounts of data. Building such a database for metabolic engineering designs requires significant manpower and is prone to human errors and bias. We propose an approach to integrate data-driven methods with genome scale metabolic model for assessment of microbial bio-production (yield, titer and rate). Using engineered E. coli as an example, we manually extracted and curated a data set comprising about 1200 experimentally realized cell factories from ~100 papers. We furthermore augmented the key design features (e.g., genetic modifications and bioprocess variables) extracted from literature with additional features derived from running the genome-scale metabolic model iML1515 simulations with constraints that match the experimental data. Then, data augmentation and ensemble learning (e.g., support vector machines, gradient boosted trees, and neural networks in a stacked regressor model) are employed to alleviate the challenges of sparse, non-standardized, and incomplete data sets, while multiple correspondence analysis/principal component analysis are used to rank influential factors on bio-production. The hybrid framework demonstrates a reasonably high cross-validation accuracy for prediction of E.coli factory performance metrics under presumed bioprocess and pathway conditions (Pearson correlation coefficients between 0.8 and 0.93 on new data not seen by the model).

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2015

Combined Heat and Power Systems Technology Development and Demonstration 370 kW High Efficiency Microturbine

The C370 Program was awarded in October 2010 with the ambitious goal of designing and testing the most electrically efficient recuperated microturbine engine at a rated power of less than 500 kW. The aggressive targets for electrical efficiency, emission regulatory compliance, and the estimated price point make the system state-of-the-art for microturbine engine systems. These goals will be met by designing a two stage microturbine engine identified as the low pressure spool and high pressure spool that are based on derivative hardware of Capstone’s current commercially available engines. The development and testing of the engine occurred in two phases. Phase I focused on developing a higher power and more efficient engine, that would become the low pressure spool which is based on Capstone’s C200 (200kW) engine architecture. Phase II integrated the low pressure spool created in Phase I with the high pressure spool, which is based on Capstone’s C65 (65 kW) commercially available engine. Integration of the engines, based on preliminary research, would allow the dual spool engine to provide electrical power in excess of 370 kW, with electrical efficiency approaching 42%. If both of these targets were met coupled with the overall CHP target of 85% total combined heating and electrical efficiency California Air Resources Board (CARB) level emissions, and a price target of $600 per kW, the system would represent a step change in the currently available commercial generation technology. Phase I of the C370 program required the development of the C370 low pressure spool. The goal was to increase the C200 engine power by a minimum of 25% — 250 kW — and efficiency from 32% to 37%. These increases in the C200 engine output were imperative to meet the power requirements of the engine when both spools were integrated. An additional benefit of designing and testing the C370 low pressure spool was the possibility of developing a stand-alone product for possible commercialization. The low pressure spool design activity focused on an aeropath derivative of the current C200 engine. The aeropath derivative included changes to the compressor section —compressor and inducer — and to the turbine nozzle. The increased power also necessitated a larger, more powerful generator and generator controller to support the increased power requirements. These two major design changes were completed by utilizing both advanced 3D modeling and computational fluid dynamics modelling. After design, modeling, and analysis, the decision was made to acquire and integrate the components for testing. The second task of Phase I was to integrate and test the components of the low pressure spool to validate power and efficiency. Acquisition of the components for the low pressure spool was completed utilizing Capstone’s current supplier base. Utilization of Capstone’s supply base for integration of the test article would allow — if the decision was made —expedited commercialization of the product. After integration of the engine components, the engine was tested and evaluated for performance and emissions. Test data analysis confirmed that the engine met all power and efficiency requirements and did so while maintaining CARB level emissions. The emissions were met without the use of any post processing or catalyst. After testing was completed, the DOE authorized — via a milestone review — proceeding to Phase II: the development of the integrated C370 engine. The C370 high pressure spool design activity required significant changes to the C65 engine architecture. The engine required a high power density generator, completely redesigned compressor stage, turbine section, recuperator, controls architecture, and intercooler stage asThe two most critical design challenges were the turbine section (the nozzle and turbine) and the controls architecture. The design and analysis of all of the components was completed and integrated into a system model. The system model — after numerous iterations — indicated that, once integrated, the engine will meet or exceed all system requirements. Unfortunately, the turbine section’s life requirements remain a technical challenge and will require continued refinement of the bi-metallic turbine wheel design and manufacturing approach to meet the life requirement at theses high temperatures. The current controls architecture requires substantial effort to develop a system capable of handling the high-speed, near real-time controls requirement, but it was determined not to be a technical roadblock for the project. The C370 Program has been a significant effort with state-of-the-art technical targets. The targets have pushed Capstone’s designers to the limits of current technology. The program has been fortunate to see many successes: the successful testing of the low pressure spool (C250), the development of new material processes, and the implementation of new design practices. The technology and practices learned during the program will be utilized in Capstone’s current product lines and future products. The C370 Program has been a resounding success on many fronts for the DOE and for Capstone.

none↗
DOE OSTI2020

Accelerating Learning with Set-Based Concurrent Engineering

The traditional design approach for product development is to develop a design based on customer requirements and technical knowledge, build the product according to the detail requirements provided, and then test the product to validate that it works as intended. The team typically starts by identifying a single design approach and spends their time validating a single design during testing. Design teams often encounter issues in the course of development with performance, manufacturability, interfaces and more. To compensate for test failures, teams often build in time into the schedule for additional design loopbacks. Further, when the loopbacks lead to change, the late changes are costly and risky, causing the team to focuses on "fixing the bare minimum" to meet cost and schedule expectations.

42 ENGINEERING↗
DOE OSTI2018

Design Considerations Which Can Simplify Manufacturing (U) [Slides]

The purpose of this paper is to recommend design considerations which can significantly reduce the time required to manufacture parts, reducing cost to manufacture parts while increasing the quality of manufactured parts and minimize the likelihood of nonconformance conditions. The product design is ultimately the responsibility of the project engineers and their design teams. This paper is not intended to supersede design requirements.

42 ENGINEERING↗
DOE OSTI2025

Design and Development of the Handling Frame Assembly Table for the NIF Sustainment Project (Draft)

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The NIF Sustainment project's goal is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, design analysis and validation, and final design. Future work will focus on building and commissioning the system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗
DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗
DOE OSTI2013

Protein engineering for metabolic engineering: Current and next-generation tools

Protein engineering in the context of metabolic engineering is increasingly important to the field of industrial biotechnology. As the demand for biologically produced food, fuels, chemicals, food additives, and pharmaceuticals continues to grow, the ability to design and modify proteins to accomplish new functions will be required to meet the high productivity demands for the metabolism of engineered organisms. We review advances in selecting, modeling, and engineering proteins to improve or alter their activity. Some of the methods have only recently been developed for general use and are just beginning to find greater application in the metabolic engineering community. We also discuss methods of generating random and targeted diversity in proteins to generate mutant libraries for analysis. Recent uses of these techniques to alter cofactor use; produce non-natural amino acids, alcohols, and carboxylic acids; and alter organism phenotypes are presented and discussed as examples of the successful engineering of proteins for metabolic engineering purposes.

Marcheschi, RJ↗
DOE OSTI2021

Bayesian optimization for chemical products and functional materials

The design of chemical-based products and functional materials is vital to modern technologies, yet remains expensive and slow. Artificial intelligence and machine learning offer new approaches to leverage data to overcome these challenges. Herein this review focuses on recent applications of Bayesian optimization (BO) to chemical products and materials including molecular design, drug discovery, molecular modeling, electrolyte design, and additive manufacturing. Numerous examples show how BO often requires an order of magnitude fewer experiments than Edisonian search. The essential equations for BO are introduced in a self-contained primer specifically written for chemical engineers and others new to the area. Finally, the review discusses four current research directions for BO and their relevance to product and materials design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Improved high temperature radiation damage tolerance in a three-phase ceramic with heterointerfaces

Abstract Radiation damage tolerance for a variety of ceramics at high temperatures depends on the material’s resistance to nucleation and growth of extended defects. Such processes are prevalent in ceramics employed for space, nuclear fission/fusion and nuclear waste environments. This report shows that random heterointerfaces in materials with sub-micron grains can act as highly efficient sinks for point defects compared to grain boundaries in single-phase materials. The concentration of dislocation loops in a radiation damage-prone phase (Al 2 O 3 ) is significantly reduced when Al 2 O 3 is a component of a composite system as opposed to a single-phase system. These results present a novel method for designing exceptionally radiation damage tolerant ceramics at high temperatures with a stable grain size, without requiring extensive interfacial engineering or production of nanocrystalline materials.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development of safety requirements for HTGRs design - 18467

The safety requirements for the design of High Temperature Gas-cooled Reactors (HTGRs), which is analogous to the IAEA specific safety requirements (SSR) for Light Water Reactor (LWR) design (IAEA SSR-2/1), has been developed by the research committee established in the Atomic Energy Society of Japan so as to incorporate the HTGR safety features demonstrated by High Temperature Engineering Test Reactor (HTTR), lessons learned from the accident of Fukushima Daiichi Nuclear Power Station and requirements for the coupling of the hydrogen production plants with nuclear plant. The safety design approach was determined to establish a high level of safety design standards by utilizing inherent safety features of HTGRs. The safety requirements is then developed using the objectives provisions tree methodology based on the safety design approach. The requirements for a structural integrity of fuel during accident conditions, for a confinement structure instead of a leak-tight pressure resistance containment vessel, for a passive residual heat removal from outside of reactor pressure vessel, etc., which are significantly different from those of LWR, are stated in the developed safety requirements. This paper describes overview of the proposed HTGR specific safety requirements. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Development of High-Performance Cast Crankshafts. Final Technical Report

The objective of this project was to develop technologies that would enable the production of cast crankshafts that can replace high performance forged steel crankshafts. To achieve this, the Ultimate Tensile Strength (UTS) of the new material needs to be 850 MPa with a desired minimum Yield Strength (YS; 0.2% offset) of 615 MPa and at least 10% elongation. Perhaps more challenging, the cast material needs to be able to achieve sufficient local fatigue properties to satisfy the durability requirements in today’s high performance gasoline and diesel engine applications. The project team focused on the development of cast steel alloys for application in crankshafts to take advantage of the higher stiffness over other potential material choices. The material and process developed should be able to produce high-performance crankshafts at no more than 110% of the cost of current production cast units, perhaps the most difficult objective to achieve. To minimize costs, the primary alloy design strategy was to design compositions that can achieve the required properties with minimal alloying and post-casting heat treatments. An Integrated Computational Materials Engineering (ICME) based approach was utilized, rather than relying only on traditional trial-and-error methods, which has been proven to accelerate alloy development time. Prototype melt chemistries designed using ICME were cast as test specimens and characterized iteratively to develop an alloy design within a stage-gate process. Standard characterization and material testing was done to validate the alloy performance against design targets and provide feedback to material design and manufacturing process models. Finally, the project called for Caterpillar and General Motors (GM) to develop optimized crankshaft designs using the final material and manufacturing processing path developed. A multi-disciplinary effort was to integrate finite element analyses by engine designers and geometry-specific casting simulations with existing materials models to optimize crankshaft cost and performance. Prototype crankshafts of the final design were to be produced and validated using laboratory bench testing and on-engine durability testing. ICME process simulation tools were used to investigate a broad range of processing concepts. These concepts included casting orientation, various mold and core materials, and various filling and feeding strategies. Each crankshaft was first simulated without gating and risers, which is termed natural solidification. The natural solidification results were used as a baseline for strategy development of each concept. Casting process simulations and ICME tools were proven to be reasonable predictors of real world results. Potential alloys were developed that could meet the project material property goals with appropriate normalization and temper treatments. For the alloys considered, post-normalization temper treatments proved to be necessary to achieve the desired yield strengths and elongations and appropriate heat treatments were designed using ICME tools. The experimental data of all the alloys were analyzed in combination with ICME tools to establish chemistry-process-structure relations. Several GM small gas engine (SGE) crankshafts were successfully cast in sand molds using two different sprue, runner, gate, riser, chill designs. These crankshafts were cast in two different steel alloys developed during the project, but casting finishing (e.g. riser removal) remains a cost challenge. A long list of future work was left unfinished when this project was unexpectedly terminated.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Systems Engineering Applied to the Development of a Wave Energy Farm.

A motivation for undertaking this stakeholder requirements analysis and Systems Engineering exercise is to document the requirements for successful wave energy farms to facilitate better design and better design assessments. A difficulty in wave energy technology development is the absence to date of a verifiable minimum viable product against which the merits of new products might be measured. A consequence of this absence is that technology development progress, technology value, and technology funding have largely been measured, associated with, and driven by technology readiness, measured in technology readiness levels (TRLs). Originating primarily from the space and defense industries, TRLs focus on procedural implementation of technology developments of large and complex engineering projects, where cost is neither mission critical nor a key design driver. The key deficiency with the TRL approach in the context of wave energy conversion is that WEC technology development has been too focused on commercial readiness and not enough on the stakeholder requirements and particularly economic viability required for market entry.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Sorting for secreted molecule production using a biosensor-in-microdroplet approach

Significance The design–build–test cycle of metabolic engineering is swiftly becoming test limited owing to advances in DNA synthesis and library design. At the same time, improving extracellular production requires high-throughput studies to detect extracellular (not intracellular) content. Traditional approaches that utilize chromatography-based analysis or plate-based fluorescence assays are relatively throughput limited and require a high degree of liquid handling. These limitations are avoided here by creating a generalizable approach for small molecule production screening. Namely, this paradigm combines “off-the-shelf” biosensors with large library screening from producing cells in a cell-type agnostic manner.

Bowman, Emily K.↗
DOE OSTI2025

Addressing genome scale design tradeoffs in Pseudomonas putida for bioconversion of an aromatic carbon source

Genome-scale metabolic models (GSMM) are commonly used to identify gene deletion sets that result in growth coupling and pairing product formation with substrate utilization and can improve strain performance beyond levels typically accessible using traditional strain engineering approaches. However, sustainable feedstocks pose a challenge due to incomplete high-resolution metabolic data for non-canonical carbon sources required to curate GSMM and identify implementable designs. Here we address a four-gene deletion design in the Pseudomonas putida KT2440 strain for the lignin-derived non-sugar carbon source, p-coumarate (p-CA), that proved challenging to implement. We examine the performance of the fully implemented design for p-coumarate to glutamine, a useful biomanufacturing intermediate. In this study glutamine is then converted to indigoidine, an alternative sustainable pigment and a model heterologous product that is commonly used to colorimetrically quantify glutamine concentration. Through proteomics, promoter-variation, and growth characterization of a fully implemented gene deletion design, we provide evidence that aromatic catabolism in the completed design is rate-limited by fumarase hydratase (FUM) enzyme activity in the citrate cycle and requires careful optimization of another fumarate hydratase protein (PP_0897) expression to achieve growth and production. A double sensitivity analysis also confirmed a strict requirement for fumarate hydratase activity in the strain where all genes in the growth coupling design have been implemented. Metabolic cross-feeding experiments were used to examine the impact of complete removal of the fumarase hydratase reaction and revealed an unanticipated nutrient requirement, suggesting additional functions for this enzyme. While a complete implementation of the design was achieved, this study highlights the challenge of completely inactivating metabolic reactions encoded by under-characterized proteins, especially in the context of multi-gene edits.

59 BASIC BIOLOGICAL SCIENCES↗