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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 OSTI2016

Static Proof Load Testing of the Sandia SWiFT 13m Blades

Pre-flown Vestas V-27 wind turbine blades will be used at the new Sandia SWiFT test facility near Lubbock,Texas. Proof load testing the blades in the flapwise direction was needed to verify the blades are still fit for service after 20 years offield operation. Testing was conducted in Building 252(A60)at the NWTC near Boulder,Colorado, between Oct 28(arrival of blades)to Dec 4,2015(completion of testing), under NREL subtasks WE141A50 and WE161A50. Single-point, quasi-static loads were applied to the blade at three independent load stations of 5.92 m, 8.69 m, and 11.62 m, using the facility gantry crane to apply the test load in the positive flapwise direction (low pressure surface in compression). Following the flapwise load cases, a single point load was applied at the 8.69 m station in the negative edgewise direction (leading edge in compression). No damage was observed due to the introduction of the proof loads. Several small pops were heard during testing on each blade, primarily during loading at the 8.69 m station. Compliance (deflection per load) varied less than 7% between all blades for all load cases. Table 3-1 summarizes the applied loads, deflections, and compliance for each blade for the flapwise test cases. Applied test loads are the raw load cell reading minus the total tare load (combined tare load of saddle and tare load for blade self weight). Deflection here is average deflection from both LE and TE string pot data.

17 WIND ENERGY↗
DOE OSTI2024

Load Test of Alum-a-Lift Serial No. 33053261

An Alum-A-Lift A800CSPD-60 (Lift) was procured to support mechanical testing of programmatic equipment. This testing will take place within the Bldg. 131 Hi Bay. The design of the Lift procured for the purposes at LLNL was a modification of a machine that had previously been engineered and sold by Alum-a-Lift, see Fig. 1. The modification was to shorten the boom from a 56 in. length to a 28 in. length. The modified design is illustrated in Fig. 2. The Lift was fabricated and shipped to LLNL, received ~ June 2022. Upon arrival, it was successfully evaluated for “no-load” performance capability. Upon inspection of the documentation provided by Alum-a-Lift, it was noted that the load test was performed to qualify the machine for a lifting capacity of 200 lb. The LLNL requirement was that the capacity of the machine be 400 lb. Conversations with the vendor, Alum-A-Lift, followed this discovery. Rather than send the machine back to the vendor for load testing, discussions concurred that LLNL would load test the machine and Alum-A-Lift would provide the relevant load test placard to be placed on the machine subsequent to the successful load test. This MESN provides documentation of the load test to qualify the Alum-a-Lift to its’ rated capacity of 400 lb.

42 ENGINEERING↗
DOE OSTI2018

Characterizing the Subsurface Using Deformation from Pumping and Surface Loading Tests

Changes in pore pressure or applied load cause deformation that can be used to characterize the subsurface. A series of field tests were conducted by measuring the deformation and pressure response from a variety of stresses at our test site in South Carolina. The site is underlain by saprolite to a depth of 30 m, and the water table in the unconfined aquifer occurs at a depth of 9 m. The types of tests performed included constant-rate pumping tests and surface point loading tests using the weight of a person or vehicle. Vertical displacement of the saprolite in response to these stresses was measured at depths of 3, 6, 9 and 11 meters in both saturated and unsaturated conditions using an extensometer with a resolution of +/- 10 nm. Results from 2.5-hr-long constant-rate pumping tests indicate a repeatable, compressive vertical strain of roughly 0.1 microstrain in the vadose zone and 1-10 microstrain in the saturated zone. Drawdown was 5 m in the pumping well and 0.1 m in a nearby (r = 9m) observation well. Under saturated conditions, the strain rate gradually decreased throughout the test in a pattern that resembles the drawdown curve in the monitoring well. In contrast, the strain in the vadose zone increased quickly early in the test, but the strain rate diminished and was negligible after approximately 30 minutes of pumping. Interestingly, drawdown in the pumping well also increased quickly over 30 minutes and remained roughly constant after that. Additional tests were conducted by applying a load (weight of a person or vehicle) at the ground surface above the extensometer and allowing the signal to stabilize before removing the load. In the vadose zone, the soil compressed rapidly and then stabilized. In the saturated zone, sudden compression was followed by additional compression at a much slower rate. A similar response was observed upon removal of the load. This transient signal in the saturated zone is interpreted to be a poroelastic effect. When a load is applied, the solid skeleton compresses and pressurizes the pore fluid, causing flow. The strain rate is then a function of pressure diffusion. Simulation of the deformation from both pumping and loading tests using an unsaturated, poroelastic finite-element model indicates that strains are sensitive to the Young’s modulus and hydraulic conductivity as functions of saturation.

well tests, strain, surface loading, hydromechanic↗
DOE OSTI2018

Discrete element modeling of deformable pinewood chips in cyclic loading test

The design of efficient lignocellulosic biomass feedstock systems is challenging, as current laboratory characterization and design methods were developed primarily for fine powders with relatively low compressibility. Here, the discrete element method (DEM) is gaining prominence as an alternative method for modeling the bulk flow and transport of particulate materials in hoppers and feeders. However, prior DEM simulations investigating the flow of wood chips modeled the particles as simple rigid geometries such as spheres, rods or blocks, and neglected the effects of particle deformability and irregular shapes. As a consequence, those simplified DEM models may not provide enough key diagnosis to help improve the design of biomass feeding and handling equipment. This work presents a bonded-sphere DEM approach for characterizing the mechanical behavior of bulk flexible, deformable pinewood chips in a cyclic stress loading test. Clustered spheres that can bend and twist via elastic bonds are used to model irregular-shape particles in real pinewood chip samples. An axial compression tester, which contains 0.06 million bonded-sphere particles (1.35 million spheres) in a quarter cylinder, is simulated with a domain size similar to the experiments. With careful calibration, the simulations have delivered the bulk densities and the bulk moduli of elasticity that are in good agreement with those measured in the corresponding experiments. However, it is also been found challenging for the present DEM model to accurately predict the overall stress-strain behavior of bulk pinewood chips, especially the large sustained plastic deformation during unloading. Additional numerical tests have shown that the adjustment in certain contact parameters (e.g. bond stiffness) can lead to profound solution improvement, but meanwhile will induce extra challenges such as increased computing time. Future work will include an elasto-plastic particle bond model to enhance the simulation fidelity.

42 ENGINEERING↗
DOE OSTI2015

Mechanical Loads Test Report for the U.S. Department of Energy 1.5-Megawatt Wind Turbine

The objective of the test was to obtain a baseline characterization of the mechanical loads of the DOE 1.5 wind turbine located at NREL. The test was conducted in accordance with the International Electrotechnical Commission (IEC) Technical Specification, IEC 61400-13 Wind Turbine Generator Systems – Part 13: Measurement of mechanical loads; First Edition 2001-06 [1]. The National Wind Technology Center (NWTC) at NREL conducted this test in accordance with its quality system procedures so that the final test report meets the full requirements of its accreditation by the American Association for Laboratory Accreditation (A2LA). NREL’s quality system requires that all applicable requirements specified by A2LA and International Standards Organization/IEC 17025 be met or to note any exceptions in the test report.

1.5 MW↗
DOE OSTI2023

CI/CD Pipeline and DevSecOps Integration for Security and Load Testing

Dominic D’Onofrio is currently a Junior studying Information and Technology at New Mexico Institute of Mining and Technology. He recently secured an Internship with NMCCoE, where he is involved with the TracerFIRE 12 project. Additionally, he is contributing to the load and security testing team by researching ways to implement pipelining and DevSecOps; this is his main project while he is at part time capacity for TracerFIRE 12. He is doing these projects to enhance his knowledge as a system administrator and gain a deeper understating of cybersecurity practices within national labs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

High-Speed Shaft Bearing Loads Testing and Modeling in the NREL Gearbox Reliability Collaborative: Preprint

Bearing failures in the high speed output stage of the gearbox are plaguing the wind turbine industry. Accordingly, the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) has performed an experimental and theoretical investigation of loads within these bearings. The purpose of this paper is to describe the instrumentation, calibrations, data post-processing and initial results from this testing and modeling effort. Measured HSS torque, bending, and bearing loads are related to model predictions. Of additional interest is examining if the shaft measurements can be simply related to bearing load measurements, eliminating the need for invasive modifications of the bearing races for such instrumentation.

17 WIND ENERGY↗
DOE OSTI2021

Representative Modules for Accelerated Thermal Cycling and Static Load Testing

In this work, we explore the influence of module size on the rate of interconnect solder bond thermomechanical fatigue (TMF) damage and the probability of cell fracture. For the solder bond TMF damage evaluation, structural mechanics models of crystalline silicon PV models are created to solve with the Finite Element Method. For the probability of cell fracture evaluation, Weibull analysis and weakest link theory are employed to resolve the probability of crystalline silicon PV cell fracture when measured as bare cells and when stressed in reduced- and full-sized modules. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module and that smaller, representative, modules must be loaded to a much higher level than their parent full-sized modules to achieve an equivalent driving force for cell fracture.

accelerated testing↗
DOE OSTI2014

Application of Combined Sustained and Cyclic Loading Test Results to Alloy 617 Elevated Temperature Design Criteria

Alloy 617 is a reference structural material for very high temperature components of advanced-gas cooled reactors with outlet temperatures in the range of 900-950°C . In order for designers to be able to use Alloy 617 for these high temperature components, Alloy 617 has to be approved for use in Section III (the nuclear section) of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. A plan has been developed to submit a draft code for Alloy 617 to ASME Section III by 2015. However, the current rules in Subsection NH for the evaluation of strain limits and creep-fatigue damage using simplified methods based on elastic analysis have been deemed inappropriate for Alloy 617 at temperatures above 1200°F (650°C). The rationale for this exclusion is that at higher temperatures it is not feasible to decouple plasticity and creep deformation, which is the basis for the current simplified rules. This temperature, 1200 °F, is well below the temperature range of interest for this material in High Temperature Gas Cooled Reactor (HTGR) applications. The only current alternative is, thus, a full inelastic analysis which requires sophisticated material models which have been formulated but not yet verified. To address this issue, proposed code rules have been developed which are based on the use of elastic-perfectly plastic (EPP) analysis methods and which are expected to be applicable to very high temperatures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Uniform Mechanical Loading Can Test for Nonuniform Loading Durability

In this work, we present a method to evaluate the equivalency between any module mechanical loading conditions. The method is developed to address the specific failure mode of glass fracture and is based on Weibull analysis and weakest link theory. It considers the varying stress profile across the module to calculate the probability of glass fracture, which is used as the metric of equivalency. An idealized nonuniform loading scheme is employed to demonstrate the method and introduce the concept of the equivalent uniform load factor: a factor applied to the maximum pressure of the nonuniform load to obtain the equivalent uniform load value. It is demonstrated that this factor is less than unity for all nonuniform load cases considered, including snow and various characters of wind loading. These significant results suggest that uniform loading may be reliably, and practically, employed to evaluate photovoltaic module glass for nonuniform loading durability.

14 SOLAR ENERGY↗
DOE OSTI2020

In-Situ Measurement of Power Loss for Crystalline Silicon Modules Undergoing Thermal Cycling and Mechanical Loading Stress Testing

An in-situ method is proposed for monitoring and estimating the power degradation of mc-Si photovoltaic (PV) modules undergoing thermo-mechanical degradation tests that primarily manifest through cell cracking, such as mechanical load tests, thermal cycling and humidity freeze tests. The method is based on in-situ measurement of the module’s dark current-voltage (I-V) characteristic curve during the stress test, as well as initial and final module flash testing on a Sun simulator. The method uses superposition of the dark I-V curve with final flash test module short-circuit current to account for shunt and junction recombination losses, as well as series resistance estimation from the in-situ measured dark I-Vs and final flash test measurements. The method is developed based on mc-Si standard modules undergoing several stages of thermo-mechanical stress testing and degradation, for which we investigate the impact of the degradation on the modules light I-V curve parameters, and equivalent solar cell model parameters. Experimental validation of the method on the modules tested shows good agreement between the in-situ estimated power degradation and the flash test measured power loss of the modules, of up to 4.31 % error (RMSE), as the modules experience primarily junction defect recombination and increased series resistance losses. However, the application of the method will be limited for modules experiencing extensive photo-current degradation or delamination, which are not well reflected in the dark I-V characteristic of the PV module.

14 SOLAR ENERGY↗
DOE OSTI2019

Performance of a Biomass Boiler in a Load Profile Test

In this report, results are presented of the performance evaluation of a modern residential cordwood-fired hydronic heater. This unit was tested under a specific load and operating profile that includes cold start, four load levels, reload, and cycling in response to an emulated thermostat. The protocol can be completed in a single day, which allows for replicate runs in about a week of testing. This can characterize variability with greater confidence than current methods used in certification testing, reduces time to conduct certification tests, and moves toward greater representative operations as the test includes start-up and requires boilers to respond to a variety of heat loads in a manner that better reflects day-to-day operations. Detailed in the report are the results of triplicate testing of one U.S. Environmental Protection Agency-certified cordwood-fired outdoor wood boiler. Cold start emissions were the greatest among all testing periods. In triplicate testing, emission output values for the cold start tests were 9.52, 4.74, and 6.63 lb/MMBtu of output for Test 1, 2, and 3, respectively. The overall emission output values for Test 1, 2, and 3 were 0.44, 0.34, and 0.19 lb/MMBtu of output, respectively. Additionally, the work in this project found significant differences in filter sampling methods with different integrated time periods. The use of real-time particulate matter emission measurement devices was explored. Specifically, sampling with one filter over a long test with various phases (cold starts, reloads, high and low burns) yielded lower particulate mass than sampling phase by phase (one filter for high burns, one filter for low burns, etc.). Perhaps the use of a real-time particulate matter emission measurement device can be used to distinguish different burn phases without having to change filters multiple times throughout a varied load test method

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Design and Initial Verification Testing of an In Situ Load Retention Aging Fixture

Load retention is a key metric used to evaluate long-term mechanical functionality of polymeric materials. Its measurement currently requires periodically removing the aging fixtures from the ovens, removing the specimens from the fixtures, and performing load testing on the specimens. The ability to perform load measurement in situ (i.e., without having to remove the specimens from the fixtures, and possibly even the ovens) would facilitate data acquisition/analysis, improve data quality, and enable uninterrupted compression of specimens which is more representative of the actual application.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Initial Testing of an In Situ Load Retention Aging Vessel

A thermal aging vessel instrumented with load cells was fabricated. The primary function of the vessel is to continuously monitor the in situ load retention of up to three compressed polymer coupons undergoing thermally accelerated aging under nitrogen. A secondary function is to enable gas sampling of the vessel headspace during thermal aging. Heating of the vessel is achieved using a custom heater jacket. To improve upon our conventional aging study methods which require periodic interruption of aging to perform load testing in an Instron machine at room temperature, this technology aims to automate/facilitate data acquisition/analysis, improve data quality, and enable uninterrupted compression of the polymer which represents the service condition. As an example case to assess functionality of the in situ vessel, the load retention of a siloxane elastomer material additively manufactured by direct-ink-writing (DIW) was measured at three different isothermal aging temperatures for ~1 month. Initial compression of the coupons while near the aging temperature was achieved by temporarily opening the heated vessel to access the interior chamber and manually tightening four nuts to drive the heated compression plate down onto the heated coupons. Initial testing demonstrated achievement of the primary load retention monitoring function. Unfortunately, the vessel leaked which prevented gas sampling; an active purge was used to maintain a nitrogen atmosphere. Welded or otherwise sealed joints, which could be implemented in a future design, would likely eliminate leak paths. To apply time-temperature superposition (TTS), a technique used to provide long-term prediction of the load retention from short-term isothermal data, the load retention needed to be calculated relative to the load at an estimated “equilibrium” time, after most of the transient viscoelastic physical relaxation occurred. The peak load immediately after compression could not be used as the load retention basis for two reasons: (1) age-related changes must be isolated from non-age-related physical relaxation before applying TTS and (2) the manual mechanism used to compress the specimens at the aging temperature was neither smooth nor repeatable which affected the peak load value. To better understand the effect of the mode of initial compression on the measured load, and possibly better estimate “equilibrium” physical relaxation times, systematic stress relaxation experiments were performed using an Instron machine with a thermal chamber. At a given temperature, the DIW polymer was compressed to a fixed strain in either a stepped or continuous manner at two different rates, then held at that strain for 24 hrs. The results indicated that, at a given temperature, the different stress relaxation curves appeared to converge to the same curve at some “equilibrium” time when the non-age-related physical relaxation was mostly complete. Though this observation suggests that the discontinuous manual compression employed by the vessel is feasible, a compression mechanism that is rapid, smooth, and repeatable would enhance its use.

36 MATERIALS SCIENCE↗