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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 OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Sensitivity Analysis of Salt Storage Cavern Mechanical Integrity Test Parameters

This report examines the sensitivity of salt cavern Mechanical Integrity Tests (MIT) to uncertainties in key test parameters. MIT's are used by cavern operators to detect and quantify leak rates in access wells in underground salt storage caverns and involve a suite of measured and assumed parameters that have a direct impact on the sensitivity of the testing to detect actual leaks from the cavern storage system. Determining the sensitivity of the testing to these different parameters provides a basis for understanding the results from, and informing the design criteria for, this type of testing. Without fully understanding the sensitivity of the test to the testing parameters, it is possible that the test results may not accurately reflect the integrity of the cavern system; an actual leak may be missed, or an intact system may be interpreted as leaking. This report reviews the main parameters included in MITs and examines how selected changes in their values can impact test results. The deviations used in the sensitivity analyses were designed to be within the ranges believed to be similar to those which may be encountered during testing. The results show that small, plausible fluctuations in some of the parameters measured values can have a significant impact on the testing results. Of the parameters studied here, the sensitivity analyses showed the order of importance to be (from highest to lowest): nitrogen-oil interface depth measurement, well bore temperature, well head pressure, and finally the internal geometry of the testing interval.

42 ENGINEERING↗
DOE OSTI2023

3D CAD Modeling and Mechanical Integration at the Mu2e Experiment at Fermilab

This abstract encapsulates a transformative summer internship at Fermilab, focusing on the Mu2e Experiment within the Mechanical Integration and 3D CAD Modeling group. The internship was characterized by a two-phase approach, with the initial month dedicated to the design of an aluminum platform tailored for DS Trench Maintenance. This phase encompassed a comprehensive exploration of structural integrity, material selection, and precision engineering principles, demonstrating an adeptness in CAD modeling and a keen eye for detail. The subsequent month saw a seamless transition into a dynamic phase of the project, wherein the intern played a pivotal role in effecting numerous adjustments across diverse sections of the 3D experiment structure. This phase demanded a nuanced understanding of the intricacies of the Mu2e Experiment and a high level of proficiency in CAD modeling.

3D CAD Modeling↗
DOE OSTI2021

Analyzing Mechanical integrity of Microwave resonant Cavity flowmeter

The microwave resonant cavity flow sensor has been proposed to address the difficulties of measuring high-temperature molten salt flow in reactor vessels. The flow sensor consists of a metallic cylindrical cavity coupled to a microwave waveguide. The cylindrical cavity has one of the flat surfaces thin enough to undergo microscopic deflection due to dynamic pressure of the exerted by the flowing fluid. Deflection of the membrane causes a shift in the microwave resonant frequency. Fluid velocity can be estimated from the calibration curve. The objective of this report is to investigate mechanical integrity of the flowmeter’s membrane. The membrane is a thin stainless-steel circular plate with a clamped edge, subjected to uniform load. By calculating the stress on the plate due to deflection and, comparing the stress to the material ultimate tensile strength and yield strength, it can be estimated if the plate will fail. If the maximum stress is greater than the yield strength, the plate will undergo plastic deformation, and the sensor will be disabled. A stress greater than the ultimate tensile strength will cause the plate to fracture. The stress on the plate was calculated with an analytic closed form solution model, and with COMSOL Structural Mechanics Module which does not involve any approximations. Stresses in both the analytic model and COMSOL numerical model were calculated for stainless steel 316 thin circular plates under room temperature conditions, where the fluid is water. The diameter of the circular plate is approximately one inch, and thickness is 10mil. Fluid flow velocity is in the range from 0.5m/s to 1m/s. The results from the two models are similar. Both the analytic model and COMSOL model showed that maximum stresses on the plate, which are at the radial boundary of the plate, are three orders of magnitude smaller than the yield strength and ultimate tensile strength. This indicates that the sensor is at a low risk of mechanical failure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Biomineralization: Integrating mechanism and evolutionary history

Calcium carbonate (CaCO 3 ) biomineralizing organisms have played major roles in the history of life and the global carbon cycle during the past 541 Ma. Both marine diversification and mass extinctions reflect physiological responses to environmental changes through time. An integrated understanding of carbonate biomineralization is necessary to illuminate this evolutionary record and to understand how modern organisms will respond to 21st century global change. Biomineralization evolved independently but convergently across phyla, suggesting a unity of mechanism that transcends biological differences. In this review, we combine CaCO 3 skeleton formation mechanisms with constraints from evolutionary history, omics, and a meta-analysis of isotopic data to develop a plausible model for CaCO 3 biomineralization applicable to all phyla. The model provides a framework for understanding the environmental sensitivity of marine calcifiers, past mass extinctions, and resilience in 21st century acidifying oceans. Thus, it frames questions about the past, present, and future of CaCO 3 biomineralizing organisms.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Advancing the mechanical integrity and fragmentation behavior of reactive projectiles

A multivariant statistical approach was used to identify treatment conditions that improve the survivability of structural reactive material (SRM) projectiles upon launch and enhance energy release upon impact. The study included both mechanical testing of projectiles as well as their reactive characterization. The projectiles were launched in a high-velocity impact-ignition testing system and impacted an anvil for vented chamber calorimetry. This study examined a link between ultimate compressive stress and combustion performance. Two treatments were applied to consolidated aluminum projectiles including annealing and addition of silica (SiO 2 ) inclusions. Results showed annealing at moderate temperatures resulted in intact SRM projectiles upon launch. Adding small concentrations (1–2 wt. %) of SiO 2 to the SRM promoted fragmentation and combustion performance upon impact. Compared to the untreated projectiles, annealing with SiO 2 inclusion processing treatments improved the energy conversion efficiency from 37–84% (for untreated projectiles) up to 54–98%. In conclusion, increasing interparticle dislocation recovery by annealing while balancing inclusions promoting fragmentation upon impact was the key to optimizing combustion performance for SRM ballistic impact applications.

42 ENGINEERING↗
DOE OSTI2023

Operando study of mechanical integrity of high-volume expansion Li-ion battery anode materials coated by Al 2 O 3

Group IV elements and their oxides, such as Si, Ge, Sn and SiO have much higher theoretical capacity than commercial graphite anode. However, these materials undergo large volume change during cycling, resulting in severe structural degradation and capacity fading. Al 2 O 3 coating is considered an approach to improve the mechanical stability of high-capacity anode materials. To understand the effect of Al 2 O 3 coating directly, we monitored the morphology change of coated/uncoated Sn particles during cycling using operando focused ion beam–scanning electron microscopy. Here, the results indicate that the Al 2 O 3 coating provides local protection and reduces crack formation at the early stage of volume expansion. The 3 nm Al 2 O 3 coating layer provides better protection than the 10 and 30 nm coating layer. Nevertheless, the Al 2 O 3 coating is unable to prevent the pulverization at the later stage of cycling because of large volume expansion.

25 ENERGY STORAGE↗
DOE OSTI2021

Unveiling enhanced oxidation resistance and mechanical integrity of multicomponent ultra–high temperature carbides

The development of a new class of multicomponent ultra-high temperature ceramics (MC-UHTCs), often referred to as high-entropy UHTCs, has gained increased interest due to the possibility of improved thermomechanical and oxidation properties. In this study, a systematic approach by gradual addition in the UHTC components ranging from a binary to a dense quaternary (Ta,Nb,Hf,Ti)C is synthesized using spark plasma sintering (SPS). The solid solutioning was the critical factor in homogenizing the composition in the multicomponent system. The segregation of NbC and HfC was seen in binary and ternary UHTC systems, while a single-phase homogeneity was observed in the quaternary UHTC improving its hardness up to 34.8 GPa. The presence of closely spaced slip lines in the MC-UHTCs enhances resistance to indentation damage up to 72% at an applied load of 200 N. The formation of complex mixed oxide phase of Hf6Ta2O17 ensued in the lower to negligible oxidation even up to 3 min of plasma exposure with temperature exceeding 2800°C. In sum, though the entropy remains medium (0.96R) for the selected system, the quaternary UHTC system undoubtedly has significantly better thermomechanical performance when compared to established baseline UHTCs. Furthermore, this raises the debate on the justification for calling a multicomponent system a “high entropy” to be seen in a new light. The developed MC-UHTCs elicits the paradigm of this new class of UHTCs expanding their potential in thermal protection systems for hypersonic applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Integrated Mechanical System Pods (CRADA Final Report)

LBNL provided input to setting the requirements related to indoor air quality and contributed to the development of metrics and test plans to evaluate prototypes of the mechanical pods, which were developed by other members of the project team. The testing of prototypes was conducted by and at Syracuse University, another project partner. LBNL also collaborated with RMI to develop a basic plan for data collection when the pods are deployed for field testing in Phase 2.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

The response field and the saddle points of quantum mechanical path integrals

Highlights: • Moyal quantum mechanics and Marinov’s path integral. • Classical and semiclassical limits of Marinov’s path integral. • Oscillating functional integrals. • Instantons of the Marinov’s path integral. In quantum statistical mechanics, Moyal’s equation governs the time evolution of Wigner functions and of more general Weyl symbols that represent the density matrix of arbitrary mixed states. A formal solution to Moyal’s equation is given by Marinov’s path integral. In this paper we demonstrate that this path integral can be regarded as the natural link between several conceptual, geometric, and dynamical issues in quantum mechanics. A unifying perspective is achieved by highlighting the pivotal role which the response field, one of the integration variables in Marinov’s integral, plays for pure states even. The discussion focuses on how the integral’s semiclassical approximation relates to its strictly classical limit; unlike for Feynman type path integrals, the latter is well defined in the Marinov case. The topics covered include a random force representation of Marinov’s integral based upon the concept of “Airy averaging”, a related discussion of positivity-violating Wigner functions describing tunneling processes, and the role of the response field in maintaining quantum coherence and enabling interference phenomena. The double slit experiment for electrons and the Bohm–Aharonov effect are analyzed as illustrative examples. Furthermore, a surprising relationship between the instantons of the Marinov path integral over an analytically continued (“Wick rotated”) response field, and the complex instantons of Feynman-type integrals is found. The latter play a prominent role in recent work towards a Picard–Lefschetz theory applicable to oscillatory path integrals and the resurgence program.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

From quantitative trait loci towards mechanisms: Linkage Integration Hypothesis Testing (LIgHT) sheds light on the mechanisms of genetically modulated stress tolerance

The goal of this work is to assess the mechanistic bases of natural genetic variations in plant responses of photosynthesis to stress. To achieve this goal, we devised the Linkage Integration Hypothesis Testing (LIgHT) approach, comparing chromosomal locations of quantitative trait loci (QTLs) for multiple phenotypes to distinguish between hypothetical mechanisms. As a use case, we explored genetic variations in photosynthesis-related processes under chilling stress in recombinant inbred lines of cowpea ( Vigna unguiculata L. Walp.). We focused on photosynthesis-related parameters measurable in high throughput and indicative of proposed chilling responses, including the states of PSI and PSII, photoprotective non-photochemical quenching, PSII photodamage, and nyctinastic leaf movements (NLMs). The patterns of QTL linkages indicated that chilling stress tolerance is genetically controlled by avoiding PSII photodamage rather than PSI damage or NLMs. This model was validated in a separate experiment measuring the rates of PSII photodamage and repair. Additional linkages suggest that chilling-induced damage to PSII is controlled by the thylakoid proton motive force and redox state of PSII. This regulation appears to be modulated by thylakoid fatty acid composition, previously associated with the same genetic loci and now supported by broader mechanistic evidence. We propose that the LIgHT approach can be broadly applied to test mechanisms underlying genetic variations.

MultispeQ↗
DOE OSTI2020

Integrated Reference Electrodes in Anion-Exchange-Membrane Electrolyzers: Impact of Stainless-Steel Gas-Diffusion Layers and Internal Mechanical Pressure

Alkaline-membrane electrolyzers operating in pure water might provide scalable low-cost H 2 production but currently lag in performance and durability compared to commercial technologies. Typically, membrane–electrode assemblies (MEAs) are optimized in electrolyzers by changing one parameter at a time and assessing the resulting system performance via two-electrode polarization and impedance measurements. These approaches are limited in their ability to assign performance changes and durability to specific electrodes or processes. We integrate a reference electrode with the MEA to separate anode and cathode responses in both polarization and impedance measurements. Here we illustrate the power of the approach by showing how the fiber diameter of stainless-steel gas-diffusion layers (GDLs) affects performance solely at the anode, while changing the thickness of the cathode GDL simultaneously affects the performance of the anode and cathode due to changes in internal pressure from mechanical compression. This finding was obscured in conventional two-electrode measurements. The work thus guides both high-performance alkaline-membrane water-electrolyzer development and illustrates a useful strategy to study structure–activity relationships in the MEA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Energy and exergy analysis of multi-stage vacuum membrane distillation integrated with mechanical vapor compression

Membrane distillation (MD) is a promising candidate for desalinating hypersaline brine, but its poor energy efficiency has remained a major barrier for widespread application. One possible solution to this issue is to recover the latent heat in the process. In this work, a multi-stage vacuum MD (MSVMD) was integrated with a mechanical vapor compressor (MVC) to enhance the latent heat recovery, and the energetic and exergetic performance of this integrated process was examined. A comprehensive energy and exergy analysis is provided to compare MSVMD and MSVMD-MVC processes for desalination of hypersaline brine. This analysis was conducted by examining the effect of the compression ratio on the energetic and exergetic performance, and the findings are reported in terms of specific thermal energy consumption (STEC), specific electricity consumption (SEC), and exergetic efficiency. The energy analysis shows that thermal energy consumption can be reduced as the compression ratio increases, due to the enhancement of latent heat recovery. The MSVMD-MVC process can be operated in a steady-state condition, without the need for thermal heat input; with STEC and SEC of 0 and 49 kWh/m 3 at the feed temperature of 50 °C and MVC compression ratio of 2.14. Moreover, exergy analysis demonstrates the efficacy of the eNRTL model in exergy calculation. Exergy destruction can be greatly reduced by increasing the compression ratio to an optimal value. For high salinity brine (124 g/L), MSVMD-MVC achieved a higher exergetic efficiency of 6.85%, compared to 2.42% in MSVMD. Furthermore, the result suggests that the application of MVC can intensify the energy efficiency and exergetic efficiency of the MSVMD system, although this process cannot outperform the current desalination technologies from the standard primary energy point of view.

42 ENGINEERING↗
DOE OSTI2025

Drying of strawberries with airborne ultrasound and other integrated dehydration mechanisms

This article presents a comprehensive investigation into the drying of strawberries using multiple dehydration methods with an emphasis on energy efficiency and sustainability. Initially, an airborne ultrasonic transducer with a frequency of 21 kHz was employed in batch operations to examine the effects of controlling parameters, including applied power, distance from the transducer plate, sample thickness, and sample holder type. The Energy Ratio, defined as the ratio of thermal energy required to evaporate moisture to ultrasonic energy, was observed to reach up to 2.2, particularly during the initial stages of drying. Subsequently, the Smart Dryer integrated airborne ultrasound (US) dehydration, slot jet reattachment (SJR) nozzle convective drying, infrared (IR) drying, and their combinations, enabling a systematic exploration of various drying conditions on the drying time and quality of strawberries. The integration of airborne US with SJR nozzles and IR drying demonstrates a promising approach for optimizing drying processes. This method not only preserves the quality of dried strawberries but also improves the energy factor to 0.88, reducing drying time by 89% compared with other conditions. Key quality attributes of the dried strawberries, such as color and water activity, were evaluated to understand the influence of each drying method. The findings highlight the potential of these integrated drying techniques as sustainable solutions for efficient and high-quality strawberry dehydration.

42 ENGINEERING↗
DOE OSTI2025

New class of tritium breeders for fusion applications: Metal-reinforced composite breeders

Commercial fusion reactors operating on a D-T fuel cycle will require a steady supply of tritium to maintain the burning plasma required for continuous power generation. Since tritium has a short half-life, there is negligible natural abundance which necessitates fusion reactors to produce their own source of tritium. Tritium is most easily produced by surrounding a fusion reactor core with lithium (Li), which reacts under the intense neutron flux leaving the reactor core to form tritium and helium. Due to the hazards and technical challenges associated with surrounding a fusion reactor core with many tons of molten Li, other Li-bearing tritium breeder materials have been pursued. Unfortunately, most of the liquid breeders historically examined are exceedingly corrosive to reactor structural materials while many solid breeders in the form of ceramics are forced to make tradeoffs between Li content and mechanical integrity. In this work, to break the historic limit between Li-density and mechanical integrity of traditional solid breeders, a new class of solid tritium breeders is developed: metal-reinforced composite (MERC) breeders. Specifically, the high Li-density of lithium oxide (Li 2 O) is exploited through the addition of a metal reinforcing phase, producing a composite breeder material exhibiting high splitting tensile strength and quasi-ductility with a Li-density greater than other leading solid breeder candidates, including lithium orthosilicate (Li 4 SiO 4 ) and lithium metatitanate (Li 2 TiO 3 ). Mechanical testing, microstructural characterization, and neutronic simulation results are presented and discussed in light of fusion reactor design considerations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Summary of Geometric Parameters and Their Effects on Performance of U-10Mo Fuel Plates

A monolithic plate-type fuel system has been under development to convert high-performance test reactors from highly enriched uranium to low-enrichment uranium fuels and is now moving into the qualification phase, a predecessor to the timely conversion of the target reactors. To qualify this fuel system, the plates must meet safety standards and perform well in a reactor. The plates must maintain mechanical integrity, exhibit geometric stability, and have stable and predictable in-reactor behavior. The requirement to maintain mechanical integrity under normal operating conditions is primarily demonstrated by successful testing. However, each high-performance reactor employs a distinct design, resulting in distinct plate geometries, with unique features, attributes, irregularities, and tolerances. Due to the abundance of such distinct geometric varieties, a single “generic” plate geometry capturing all extremes is not achievable. It is also impractical to test each of these proposed designs in a reactor. This limitation necessitates cautious evaluations since the thermomechanical response of a plate with a certain geometry may not be representative for a plate with a significantly different geometry. To address concerns related to in-reactor plate performance, large set of sensitivity studies were performed. These parametric studies aimed to better understand irradiation performance, while evaluating the sensitivity of results to various modeling inputs, including geometric, operational, and material parameters. This work studied selected geometric parameters based on provided fuel specifications and performed a series of parametric simulations. The resulting temperature, displacement, and stress strains were comparatively evaluated to determine the effects of various geometric parameters. This draft provides a “high-level summary” of our parametric sensitivity studies and summarizes the key findings.

42 ENGINEERING↗
DOE OSTI2024

Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.

design optimization↗