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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 OSTI2025

A hereditary integral, transient network approach to modeling permanent set and viscoelastic response in polymers

An efficient numerical framework is presented for modeling viscoelasticity and permanent set of polymers. It is based on the hereditary integral form of transient network theory, in which polymer chains belong to distinct networks each with different natural equilibrium states. Chains continually detach from previously formed networks and reattach to new networks in a state of zero stress. The free energy of these networks is given in terms of the deformation gradient relative to the configuration at which the network was born . A decomposition of the kernel for various free energies allows for a recurrence relationship to be established, bypassing the need to integrate over all time history. The technique is established for both highly compressible and nearly incompressible materials through the use of neo-Hookean, Blatz–Ko, Yeoh, and Ogden-Hill material models. Multiple examples are presented showing the ability to handle rate-dependent response and residual strains under complex loading histories.

Finite element method↗
DOE OSTI2021

Constitutive Model of Radiation Aging Effects in Filled Silicone Elastomers under Strain

Filled silicone elastomers, an essential component in many technological applications, are often subjected to controlled or unintended radiation for a variety of reasons. Radiation exposure can lead to permanent mechanical and structural changes in the material, which is manifested as altered mechanical response, and in some cases, a permanent set. For unfilled elastomers, network theories developed and refined over decades can explain these effects in terms of chain-scission and cross-link formation and a hypothesis involving independent networks formed at different strain levels of the material. In this work, we expose a filled silicone rubber to gamma radiation while being under finite elongational strain and show that the observed mechanical and structural changes can be quantitatively modeled within the same theoretical framework developed for unfilled elastomers as long as nuances associated with the Mullins effect are accounted for in a consistent manner. In this work, we employ Ogden’s incompressible hyperelastic model within the framework of Tobolsky’s two-network scheme to describe the observed permanent set and mechanical modulus changes as a function of radiation dosage. In the process, we conclude that gamma radiation induces both direct cross-linking at chain crossings (H-links) and main-chain-scission followed by cross-linking (Y-links). We provide an estimate of the ratio of chain-scission to cross-linking rates, which is in reasonable agreement with previous experimental estimate from Charlesby–Pinner analysis. We use density functional theory (DFT)-based quantum mechanical calculations to explore the stability of –Si and –SiO radicals that form upon a radiation-induced chain-scission event, which sheds light on the relative rates of Y-linking and H-linking processes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

3D printable silicone compositions exhibiting high toughness and low durometer

3D printable silicones can be designed with varying crosslink density, network structures, and types of reinforcing additives. Within this design space, one may tailor the uncured material’s rheology and mechanical response to access a wide range of potential applications. However, printable, low modulus silicones, particularly those applicable to direct ink write, are underreported in published literature. To address the need for higher performance, low modulus silicones with demonstrated printability, a new set of ca. 20–50 Shore A hardness silicone elastomers exhibiting ca. 7 MPa ultimate tensile strength and ca. 400–1200% elongation at break is presented. Mechanical properties were analyzed, providing insight to the effects of formulation constituents on mechanical properties. Cyclic mechanical testing of the silicone formulations was also performed, and the energy loss and permanent set throughout cycling were determined. In conclusion, printed structures demonstrate the feasibility of these new silicones as durable frameworks for novel soft device applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A physics-informed multi-agents model to predict thermo-oxidative/hydrolytic aging of elastomers

This paper introduces a novel physics-informed multi-agents constitutive model to propose prediction in quasi-static constitutive behavior of cross-linked elastomer and the loss of mechanical performance during environmental aging. The presented model is used to simulate the effect of single-mechanism chemical aging (i.e. thermal-inducedor hydrolytic aging) on the behavior of the material in this hybrid framework. Those environmental single-mechanism damages change the polymer matrix over time due to massive chain scission, chain formations, and changing the arrangement of molecules in the polymer matrix. Here we propose a data-driven super-constrained machine-learned engine to represent damage in the polymer matrix and capture the changes in material behavior, including its inelastic features such as Mullins effect and permanent set in the course of aging. We have simplified the 3D stress–strain tensor mapping problem into a small number of super-constrained 1D mapping problems by means of a sequential order reduction. An assembly of multiple replicated conditional neural-network learning-agents (L-agents) is trained to systematically simplify the high-dimensional mapping problem into multiple 1D problems, each represented by a different type of agent. Our hybrid framework is designed to capture the effect of deformation history, aging time, and aging temperature. The model is validated with respect to a comprehensive set of experiments specifically designed to benchmark model capabilities and also against available data in the literature. Thermodynamic consistency and frame independency have been verified. Besides acceptable predictive abilities, a significant reduction of computational cost to predict behavior at multiple states of deformation is the most significant feature of this model.

42 ENGINEERING↗
DOE OSTI2020

A multi-physics constitutive model to predict hydrolytic aging in quasi-static behaviour of thin cross-linked polymers

The effect of hydrolytic aging on mechanical quasi-static responses of rubber-like materials, in particular, the idealized Mullins effect and permanent set have been modeled. The effect of hydrolytic damage on the mechanical integrity of the polymer matrix is modeled as the direct competition of two micro-structural phenomena (i) chain scission and (ii) reduction of cross-links. Both phenomena and their correlation were modeled and thus, the strain energy of the polymer matrix is written with respect to three independent mechanisms; i) the shrinking original matrix that has not been attacked by water, ii) conversion of the first network to a new network due to the reduction of the cross-links, and iii) energy loss from network degradation due to water attacks to polymer active agents. The proposed model satisfies the Clausius-Duhem inequality and is thus physically feasible. The model is validated with respect to sets of our experimental data and other sets available in the literature. The proposed model is based on the assumption of homogeneous diffusion and mainly relevant for thin samples. In view of its accuracy, interpret-ability, and deep insight it provides into the nature of damage accumulation, the model is a good choice for further implementation in FE applications.

42 ENGINEERING↗
DOE OSTI2020

Hydrolytic Aging in Rubber-Like Materials: A Micro-Mechanical Approach to Modeling

Abstract The effect of hydrolytic aging on mechanical responses of Rubber likes materials, in particular, Mullins effect and the permanent set has been modeled. Hydrolytic aging is considered as the result of the competition between two phenomena (1) chain scission and (2) cross-link scission/reformation. Both phenomena were modeled and thus, the strain energy of the polymer matrix is written with respect to three independent mechanisms; i) the shrinking original matrix which has not been attacked by water, ii) conversion of the first network to a new network due to the reduction of the crosslinks, and iii) energy loss from network degradation due to water attacks to ester groups. The model is validated with respect to a set of experimental data. Besides accuracy, the simplicity and few numbers of fitting parameters make the model a good choice for further implementations.

Bahrololoumi, Amir↗
DOE OSTI2023

A Physics-Based Data-Driven Approach for Modeling of Environmental Degradation in Elastomers

Abstract Elastomers are now commonly used in a number of industries, including aerospace, structure, transportation, shipbuilding, and automotive, due to their excellent workability, formability, and flexibility. During their activity, elastomers are subjected to harsh environmental conditions, which decreases their resilience. False predictions made early in their lives can have major financial and environmental implications. Elastomers’ performance and properties, such as strength, durability, and density, are influenced by chemical changes in these materials, known as degradation, which occurs over time. This process can alter the morphology of a polymer matrix as well as cause chain scission and cross-linking, resulting in different behaviors than that of the unaged material. To demonstrate the effect of thermaloxidative aging on the mechanical behavior of elastomers, several experimental and theoretical models have been proposed. In view of the large volume of experimental data available on micro-structural evolution in the course of aging, we propose a physics-based data-driven approach to overcome the shortcomings of both phenomenological and micro-mechanical models. This work presents a novel thermodynamically consistent, multiagent machine-learned model for predicting the constitutive behavior of cross-linked elastomers during environmental aging, such as thermo-oxidative and hydrolytic aging for various states of deformation. Single mechanism degradation changes the polymer matrix over time where it is causing chain scission, reduction of cross-links, and morphology change. To capture the idealized Mullins effect and permanent set due to the effect of single aging mechanisms on nonlinear mechanical responses of elastomers, we propose a data-driven model for simulating inelastic elements in a polymer matrix. By using a sequential order reduction, we were able to reduce the 3D stress-strain tensor mapping problem to a small number of super-constrained 1D mapping problems. To systematically classify such mapping problems into a few categories, an assembly of multiple replicated conditional neural network learning agents (L-agents) is used based on our recent work. Each category is represented by a different type of agent. The effect of deformation history, aging time, and aging temperature is captured by this model. The model is validated using a broad collection of data, ranging from our experimental results to data from the literature. In addition, thermodynamic consistency and frame independence are investigated. The most significant achievements of this model are its precision, simplicity, and prediction of inelasticity under various states of deformation. The model’s accuracy and simplicity make it a good option for commercial and industrial applications. Conveniently, due to the model modular nature, it can be expanded in the future to include viscoelasticity and non-isotropic formation for better precision.

Ghaderi, Aref↗
DOE OSTI2023

A novel scheme for error field correction in permanent magnet stellarators

Stellarators offer a promising path towards fusion reactors, but their design and construction are complicated by stringent tolerance requirements on highly complex 3D coils. A potential way to simplify the engineering requirements for stellarators is to use simple planar toroidal field coils along with permanent magnet arrays to generate shaping fields. In order to ensure sufficient field accuracy while minimizing engineering complexity and system cost, new techniques are required to correct the field produced by the permanent magnet arrays to within requirements set by plasma physics. This work describes a novel correction method developed for this purpose. This analysis is applied to the design of a quasi-axisymmetric stellarator that employs a combination of permanent magnets and planar toroidal field coils to generate its magnetic field. Analysis techniques and initial results using the method for error correction on a proposed permanent magnet stellarator are shown, and it is demonstrated that the method successfully meets the design requirements of the project.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Design of an arrangement of cubic magnets for a quasi-axisymmetric stellarator experiment

The usage of permanent magnets to shape the confining magnetic field of a stellarator has the potential to reduce or eliminate the need for non-planar coils. As a proof-of-concept for this idea, here we have developed a procedure for designing an array of cubic permanent magnets that works in tandem with a set of toroidal-field (TF) coils to confine a stellarator plasma. All of the magnets in the design are constrained to have identical geometry and one of three polarization types in order to simplify fabrication while still producing sufficient field accuracy. We present some of the key steps leading to the design, including the geometric arrangement of the magnets around the device, the procedure for optimizing the polarizations according to the three allowable magnet types, and the choice of magnet types to be used. We apply these methods to design an array of rare-Earth permanent magnets that can be paired with a set of planar TF coils to confine a quasi-axisymmetric plasma with a toroidal magnetic field strength of about 0.5 T on axis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Design of an arrangement of cubic magnets for a quasi-axisymmetric stellarator experiment

The usage of permanent magnets to shape the confining field of a stellarator has the potential to reduce or eliminate the need for non-planar coils. As a proof-of-concept for this idea, we have developed a procedure for designing an array of cubic permanent magnets that works in tandem with a set of toroidal-field coils to confine a stellarator plasma. All of the magnets in the design are constrained to have identical geometry and one of three polarization types in order to simplify fabrication while still producing sufficient field accuracy. We present some of the key steps leading to the design, including the geometric arrangement of the magnets around the device, the procedure for optimizing the polarizations according to three allowable magnet types, and the choice of magnet types to be used. We apply these methods to design an array of rare-Earth permanent magnets that can be paired with a set of planar toroidal-field coils to confine a quasi-axisymmetric plasma with a toroidal magnetic field strength of about 0.5 T on axis.

Hammond, Kenneth↗
DOE OSTI2023

Greedy permanent magnet optimization

Abstract A number of scientific fields rely on placing permanent magnets in order to produce a desired magnetic field. We have shown in recent work that the placement process can be formulated as sparse regression. However, binary, grid-aligned solutions are desired for realistic engineering designs. We now show that the binary permanent magnet problem can be formulated as a quadratic program with quadratic equality constraints, the binary, grid-aligned problem is equivalent to the quadratic knapsack problem with multiple knapsack constraints, and the single-orientation-only problem is equivalent to the unconstrained quadratic binary problem. We then provide a set of simple greedy algorithms for solving variants of permanent magnet optimization, and demonstrate their capabilities by designing magnets for stellarator plasmas. The algorithms can a-priori produce sparse, grid-aligned, binary solutions. Despite its simple design and greedy nature, we provide an algorithm that compares with or even outperforms the state-of-the-art algorithms while being substantially faster, more flexible, and easier to use.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Mitigate Stress Corrosion Cracking (SCC) in High-strength Al Castings (CRADA 508)

Development of high strength, corrosion resistant, aluminum alloys is important to a number of industries, including automotive, aerospace, power, etc. Understanding how processing methods such as casting, chemistry, additives and recycle content affect an alloy’s microstructure and performance in real world environments is crucial to their implementation. One major concern is how the repeated exposure to saline solutions can be detrimental to the structural integrity of aluminum alloy components. This study was undertaken as a collaboration between Eck Industries and PNNL to investigate the stress corrosion cracking (SCC) and corrosion behavior of aluminum alloys. This work examines the SCC response of three different materials set. First is cast A206 Al alloy produced by three different casting techniques (i.e., permanent mold, and sand casting with and without chill) and with or without nano forming additives as potential grain refiners. The second materials set comprises Al alloy tubes extruded by PNNL’s ShAPE process and produced using raw material with three different ratios of twitch and pre-consumer Al 6061 scrap. Finally, the third materials set comprises two Al-Si-Mg-Fe alloys with controlled Si% and Fe% to mimic recycle grade Al alloys. The corrosion behavior of these materials was characterized using SCC testing and scanning electrochemical cell microscopy (SECCM) technique; mechanical behavior was characterized using tensile testing, and microstructure was characterized using optical and electron microscopy techniques. Of the A206 Al alloys, the samples with nano forming additives performed poorly compared to those without. The best SCC performance (i.e. least degradation in mechanical properties) was demonstrated by A206 alloy sand cast with chill while the permanent mold sample showed the worst SCC performance. The SECCM was performed on A206 alloy sand cast with chill to understand the effect of microstructure and determine the location-dependent corrosion properties on grain boundaries (GB) and inside grains (IG) on the sample. The corrosion potential and current measured on GB and IG at various points on the sample established that the GB locations are more cathodic and corrosive than the IG locations. Further work needs to be conducted to investigate the mechanisms behind the observed dependence of SCC on casting technique and nano forming additives. Among the ShAPE extruded tubes, SECCM data suggests the decreasing order of tendency to corrode as follows: 100% twitch > 75% twitch > 50% twitch. Finally, both variants of the Al-Si-Mg-Fe alloys showed a large volume fraction of Fe- and Si-containing intermetallics and additional work is needed to discern differences in their respective corrosion responses. In summary, correlating local electrochemical behavior (e.g. via SECCM) with micro/nanostructure, in conjunction with bulk mechanical behavior, can help identify the right fabrication method and alloy chemistry to minimize SCC issues in Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2026

2005 Tahoe Regional Household Travel Survey

The 2005 Tahoe Regional Household Travel Survey is a comprehensive survey of the travel patterns of households in the Tahoe Basin region of California and Nevada. The survey was conducted for the Tahoe Regional Planning Agency over a four-month period, from June through September 2005. This collection contains two sets of travel data: 1) a survey of 1,220 permanent households within the Tahoe Basin region and 2) a subset survey of 125 seasonal households within the same area. The permanent resident dataset contains information about 2,732 household members, 2,471 vehicles, and 11,048 trips made during a 24-hour period. The seasonal resident subset features 726 trip observations and information about 229 household members and 185 vehicles. The survey relied on the willingness of study area residents to 1) provide demographic information about their household, its members, and its vehicles and 2) document all travel for each household member, regardless of age, over an assigned 24-hour period. During the recruitment phase, respondents were asked to provide detailed household information, including permanent or seasonal resident status, number of household occupants, type of dwelling unit, number of vehicles available to household members, as well as the year, body type, and fuel type of each vehicle. Survey participants received mailed travel logs to aid in documenting travel information for the 24-hour assessment period. Respondents were instructed to record their mode of transportation, trip purpose, number of passengers, departure and arrival times, activities at each trip destination, ride fare, and parking costs. Demographic information for this study includes age, gender, income, education, and employment status.

1Hz data↗
DOE OSTI2022

A very high energy hadron collider on the Moon

Abstract The long-term prospect of building a hadron collider around the circumference of a great circle of the Moon is sketched. A circular collider on the Moon (CCM) of ∼11 000 km in circumference could reach a proton–proton center-of-mass collision energy of 14 PeV—a thousand times higher than the Large Hadron Collider at CERN—optimistically assuming a dipole magnetic field of 20 T. Several aspects of such a project are presented, including siting, construction, availability of necessary materials on the Moon, and powering, as well as a discussion of future studies and further information needed to determine the more concrete feasibility of each. Machine parameters and vacuum requirements are explored, and an injection scheme is delineated. Other unknowns are set down. Due to the strong interest from multiple organizations in establishing a permanent Moon presence, a CCM could be the (next-to-) next-to-next-generation discovery machine for high-energy particle physics and a natural successor to next-generation machines, such as the proposed future circular collider at CERN or a super proton–proton collider in China, and other future machines, such as a collider in the Sea, in the Gulf of Mexico. A CCM would serve as an important stepping stone toward a Planck-scale collider sited in our Solar System.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

WBG-Enabled Current-Source Inverters for Integrated PM Motor Drives

This project takes advantage of the special capabilities of wide-bandgap (WBG) power semiconductor devices to develop innovative power electronics in the form of new current-source inverters (CSIs) that offer promising advantages over the dominant voltage-source inverter (VSI) topology. These CSIs, in turn, are extremely well-suited for integration into the housings of permanent magnet synchronous machines (PMSMs) to form integrated motor drives (IMDs). These new IMDs offer great promise for achieving major energy savings in a wide variety of applications that benefit from adjustable-speed control, including air conditioners, laundry appliances, industrial pumps/compressors, electric vehicles, and aerospace drives. WBG devices play a critical enabling role in these new IMDs because of their transformative features including much higher switching frequencies, lower losses, and compatibility with high operating temperatures. When incorporated into new CSI-based IMDs with PM machines, these WBG switches open the door to achieving major increases in power density, drive system efficiency, and fault tolerance, as well as substantial reductions in electromagnetic interference (EMI), manufacturing cost, and temperature-induced failures. The higher operating temperature capability of WBG devices compared to conventional silicon power devices is very appealing in IMD applications because the power electronics is mounted in close proximity to the motors which typically operate at temperatures well above the maximum limits of today’s silicon-based power electronics. This project has succeeded in designing, building, and testing multiple prototype versions of this CSI-IMD that have overcome many technical challenges in order to demonstrate the impressive performance improvements that can be achieved by the WBG-enabled CSI-IMD. The preliminary demo and bench-top versions of the current-source inverter developed during the first two years of the project were critical to laying the technical foundations for the 3 kW prototype CSI-IMD unit that was successfully built and tested during the third year. This prototype CSI-IMD unit was designed to fit within the housing envelope of the original permanent magnet (PM) synchronous machine in order to meet the demanding power density requirements that were set at the beginning of the project. All of the remaining performance objectives set for the prototype CSI-IMD unit including efficiency and electromagnetic interference (EMI) were also met. The last 18 months of the project were devoted to developing further enhancements of the WBG-enabled CSI-IMD technology that better prepare it for commercial production. More specifically, an upgraded version of the prototype CSI-IMD unit was developed that moved the power electronics into the same machine housing chamber as the motor, substantially raising the thermal demands on the power electronics. Tests with five different combinations of motor enclosure types and air cooling configurations were evaluated. Importantly, this work confirmed that the power electronics can deliver its full rated power and still operate well within its maximum temperature limits even for worst-case conditions when the housing is “totally-enclosed” without any openings for air to enter or exit the enclosure, and no blower/fan is provided to blow air over the outside surface of the enclosure. Reaching the full performance and energy-savings potential of this disruptive CSI-IMD motor drive technology is highly consistent with ARPA-E’s stated mission to “enhance the economic and energy security of the United States” while also supporting its commitment to “ensure that the U.S. maintains a technological lead in developing and deploying advanced energy technologies”. Follow-on projects are under way to explore the scalability of WBG-enabled CSI-IMD technology to 100 kW (peak) electric vehicle traction drives and fault-tolerant modular motor drives for future electrified aircraft propulsion applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Interdigital Capacitance Sensor for Cable Insulation Test and Monitoring

A substantial body of work suggests feasibility to measure cable jacket and insulation conditions using various forms of interdigital capacitance (IDC) sensors. The sensors can either be used to manually test local cable conditions or as permanently installed sensors. Eligible cables subject to these measurements do not include shielded cables but the set of candidate cables is expanded from only unjacketed cables by the ability to assess insulation condition through the jacket. Dual gap IDC sensors are confirmed to be able to sense the insulation condition beneath a polymer jacket and, moreover, the IDC is the only known way to assess the insulation condition through the jacket. PNNL has filed a patent for this approach and is exploring commercial partnerships to exploit IDC technology for actionable field measurements.

NDE, cable, IDC, capacitance, permittivity, insula↗
DOE OSTI2021

Programs and Code for Geothermal Exploration Artificial Intelligence

The scripts below are used to run the Geothermal Exploration Artificial Intelligence developed within the "Detection of Potential Geothermal Exploration Sites from Hyperspectral Images via Deep Learning" project. It includes all scripts for pre-processing and processing, including: - Land Surface Temperature K-Means classifier - Labeling AI using Self Organizing Maps (SOM) - Post-processing for Permanent Scatterer InSAR (PSInSAR) analysis with SOM - Mineral marker summarizing - Artificial Intelligence (AI) Data splitting: creates data set from a single raster file - Artificial Intelligence Model: creates AI from a single data set, after splitting in Train, Validation and Test subsets - AI Mapper: creates a classification map based on a raster file

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Predicted Ferromagnetism in Discovered Co–Bi Binary Phases

Binary solid-state materials offer unique insight into how the interplay of factors such as stoichiometry and bonding interactions affects magnetism and electronic properties. In this work, we considered systems where a transition metal provides the spin moment and a heavy main group element bolsters strong spin–orbit coupling. Within this context, cobalt, a known component of permanent magnets, and bismuth, functionally the heaviest element stable to radioactive decay, form a compelling combination. The Co–Bi system has been previously shown to exhibit superconductivity in a phase recovered from high pressure. We expected the Co−Bi system could also be ferromagnetic, resulting in two sets of compounds within one chemical system, one superconducting and one ferromagnetic. Subsequently, we investigated the Co–Bi system through both experimental and theoretical approaches to discover new candidates for permanent magnets. Ab initio random structure searching calculations identified five new compounds with diverse structural motifs that may form at higher pressures than previously reported. Experimental high-pressure synthesis yielded four compounds: α-CoBi, α-CoBi 2 , β-CoBi, and β-CoBi 2 . Three of these phases, α-CoBi 2 , β-CoBi, and β-CoBi 2 , were consistent with the calculated structures, corresponding to a 60% success rate for our structure search and underscoring the strength of combining computation with experiment. Theory predicts β-CoBi and β-CoBi2 are ferromagnetic, with β-CoBi possessing larger magnetocrystalline anisotropy energy than familiar permanent magnets such as CoPt and Nd–Fe–B. These results suggest the Co–Bi system could be a platform for understanding the factors that underpin magnetism and, to an extent, superconductivity in a chemically simple binary system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗