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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

Design and Analysis Progress of ITER Diagnostic Equatorial Port #09

ITER is the world's largest fusion device currently under construction in the South of France with >50 diagnostic systems to be installed inside the port plugs (PPs), the interspace (IS), or the port cell region of various diagnostic ports. The plasma facing diagnostic first wall (DFW) and its supporting diagnostic shield modules (DSM) are designed to protect front-end diagnostics from plasma neutron and plasma radiation, while providing apertures for diagnostic access to the plasma. The design of ITER port plug structures including the DFW and the DSM is largely driven by the electromagnetic loads included on the PP structural components during plasma major disruptions and the vertical displacement events (VDEs). Unlike DFW and DSM, the design of diagnostic system, however, is likely driven by the steady-state thermal loads from plasma volumetric and surface heating and the dynamic response of the in-port components attached to the port-specific DSM or closure plate under transient loads induced on the vacuum vessel and the port extension during asymmetric VDEs. Three tenant diagnostic systems are integrated into the equatorial port 09. The toroidal interferometer/polarimeter, or TIP system, is installed in the left drawer (DSM3, left looking from plasma) for measuring the plasma density so to control the fuel input. The electron cyclotron emission (ECE) system is installed in the middle drawer (DSM2) to provide the high spatial and temporal resolution measurements of electron temperature evolution and the electron thermal transport inferences. The visible/infrared wide angle viewing system is installed in the right drawer (DSM1) to provide visible and infrared viewing and temperature data of the first wall for its protection in support of machine operation. The port plug integration design and multiphysics analyses are performed following port integration requirements including the weight limit (45 tones total), shut down dose rate limits, the cooling/heating and structural integrity validation. Mass distribution for TIP and ECE DSMs has been optimized to minimize the total weight by a new design of the boron carbide shielding pocket. Furthermore, the lightened DSM maintains its front-end load distribution and the structural stiffness with minimum impact to the DFW so to better protect on-board diagnostics; while still provides sufficient front-end stiffness for its structural integrity as well as the diagnostics function requirements.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Mid-height seismic isolation of equipment in nuclear power plants: Numerical simulations and design recommendations

Seismic isolation can mitigate earthquake demands on safety-class equipment and is being considered for application to some advanced nuclear reactors. For tall, slender vessels that could represent an advanced reactor, a steam generator or a heat exchanger, mid-height seismic isolation has been shown to be beneficial and practical. Here, this paper focuses on numerical modeling of a mid-height isolated tall, slender vessel with two primary goals 1) investigate and quantify the benefits of mid-height seismic isolation for a range of support structure stiffnesses, isolation systems, and seismic inputs, and 2) provide analysis and design recommendations for isolation of safety-class equipment. Results of response-history analysis were in good agreement with experimental measurements and demonstrated that mid-height isolation can substantially reduce seismic demands on tall, slender vessels for a range of support structure stiffnesses, isolation systems, and seismic inputs. Importantly, the reductions in horizontal spectral accelerations in the mid-height isolated vessel from the non-isolated condition were not affected by the stiffness of the support structure. Recommendations are made for analysis and design of isolated equipment and testing of isolators used for equipment protection in nuclear facilities, which are also applicable to other industries.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Data Sciences Summer Institute Topology Optimization

DSSI_TOPOPT is a 2D topology optimization code that designs stiff structures made of a single linear elastic material and void space. The code generates a finite element mesh of a rectangular design domain on which the user specifies displacement and load boundary conditions. The code iteratively designs a structure that minimizes the compliance (maximizes the stiffness) of the structure under the given loading, subject to an upper bound on the amount of material used. Depending on user options, the code can evaluate the performance of a user-designed structure, or create a design from scratch. Output includes the finite element mesh, design, and visualizations of the design.

Watts, Seth↗
DOE OSTI2024

First considerations on the supporting structures of FCC-ee booster and collider in the arc regions

In 2022, the FCC Feasibility Study management mandated a working group to analyse the best configuration of the FCC-ee tunnel in the arc regions, in view of the construction of a mock-up of the arc half-cell. One of the main and most challenging goals of the study, named FCC-ee Arc Half-Cell Mock-up Project, was to perform a preliminary investigation on the principles of supporting the Short-Straight Sections and dipoles of the half-cells, both for the booster and for the collider machines. This is an important input needed for the choice of the best configuration of the relative placement of the booster with respect to the collider. The structural stiffness, mass and stability of the supporting structures must be optimized to minimize the vibrations transmitted/transferred to the magnetic system of the accelerators by elements such as pumps, water cooling system, beam thermomechanical stresses, powering elements, etc. To perform the study, tools such as CAD software, FEM and analytical techniques were employed. This paper summarizes the preliminary design concepts and the results of the simulations performed.

Accelerator Subsystems and Technologies↗
DOE OSTI2021

Plastic work constrained elastoplastic topology optimization

An elastoplastic topology optimization framework for limiting plastic work generation while maximizing stiffness is presented. The kinematics and constitutive model are based on finite strain linear isotropic hardening plasticity, and the balance laws are solved using a total Lagrangian finite element formulation. Aggregation of the specific plastic work combined with an adaptive normalization scheme efficiently constrains the maximum specific plastic work. The optimization problem is regularized using an augmented partial differential equation filter, and is solved by the method of moving asymptotes where path-dependent sensitivities are derived using the adjoint method. The numerical examples show a clear dependence on the optimized maximum stiffness structures for different levels of constrained specific plastic work. It is also shown that due to the history dependency of the plasticity, the load path significantly influences the structural performance and optimized topology.

42 ENGINEERING↗
DOE OSTI2015

Precision mechanical structure of an ultra-high-resolution spectrometer for inelastic X-ray scattering instrument

A method and an ultrahigh-resolution spectrometer including a precision mechanical structure for positioning inelastic X-ray scattering optics are provided. The spectrometer includes an X-ray monochromator and an X-ray analyzer, each including X-ray optics of a collimating (C) crystal, a pair of dispersing (D) element crystals, anomalous transmission filter (F) and a wavelength (W) selector crystal. A respective precision mechanical structure is provided with the X-ray monochromator and the X-ray analyzer. The precision mechanical structure includes a base plate, such as an aluminum base plate; positioning stages for D-crystal alignment; positioning stages with an incline sensor for C/F/W-crystal alignment, and the positioning stages including flexure-based high-stiffness structure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additively Manufactured Shock Absorbing Engineered Materials

This study investigates the static and dynamic mechanical performance of conformal negative stiffness honeycomb structures. Negative stiffness honeycombs are capable of elastically absorbing a static or dynamic mechanical load at a predefined force threshold and returning to their initial configuration after the load is released. Most negative stiffness honeycombs rely on mechanical loading that is orthogonal to the base of the structure. In this study, a more three-dimensional design is presented that allows the honeycomb to conform to complex surfaces and protect against impacts from multiple directions. The conformal designs are additively manufactured in nylon and stainless steel and subjected to quasi-static mechanical loading and dynamic mechanical impact tests that demonstrate their impact protection capabilities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Prediction of carbon nanostructure mechanical properties and the role of defects using machine learning

Graphene-based nanostructures hold immense potential as strong and lightweight materials, however, their mechanical properties such as modulus and strength are difficult to fully exploit due to challenges in atomic-scale engineering. This study presents a database of over 2,000 pristine and defective nanoscale CNT bundles and other graphitic assemblies, inspired by microscopy, with associated stress–strain curves from reactive molecular dynamics (MD) simulations using the reactive INTERFACE force field (IFF-R). These 3D structures, containing up to 80,000 atoms, enable detailed analyses of structure-stiffness-failure relationships. By leveraging the database and physics- and chemistry-informed machine learning (ML), accurate predictions of elastic moduli and tensile strength are demonstrated at speeds 1,000 to 10,000 times faster than efficient MD simulations. Hierarchical Graph Neural Networks with Spatial Information (HS-GNNs) are introduced, which integrate chemistry knowledge. HS-GNNs as well as extreme gradient boosted trees (XGBoost) achieve forecasts of mechanical properties of arbitrary carbon nanostructures with only 3 to 6% mean relative error. The reliability equals experimental accuracy and is up to 20 times higher than other ML methods. Predictions maintain 8 to 18% accuracy for large CNT bundles, CNT junctions, and carbon fiber cross-sections outside the training distribution. The physics- and chemistry-informed HS-GNN works remarkably well for data outside the training range while XGBoost works well with limited training data inside the training range. The carbon nanostructure database is designed for integration with multimodal experimental and simulation data, scalable beyond 100 nm size, and extendable to chemically similar compounds and broader property ranges. The ML approaches have potential for applications in structural materials, nanoelectronics, and carbon-based catalysts.

Winetrout, Jordan J.↗
DOE OSTI2020

Experimental Modal Analysis Using Phase Quantities from Phase-Based Motion Processing and Motion Magnification

Phase-based motion processing and the associated Motion Magnification that it enables has become popular not only for the striking videos that it can produce of traditionally stiff structures visualized with very large deflections, but also for its ability to pull information out of the noise floor of images so that they can be processed with more traditional optical techniques such as digital image correlation or feature tracking. While the majority of papers in the literature have utilized the Phase-based Image Processing approach as a pre-processor for more quantitative analyses, the technique itself can be used directly to extract modal parameters from an image, noting that the extracted phases are proportional to displacements in the image. Therefore, once phases are extracted, they can be fit using traditional experimental modal analysis techniques. This produces a mode “shape” where the degrees of freedom are phases instead of physical motions. These phases can be scaled to produce on-image visualizations of the mode shapes, rather than operational shapes produced by bandpass filtering. Modal filtering techniques can also be used to visualize motions from an environment on an image using the modal phases as a basis for the expansion.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Reactivity descriptors in acid catalysis: acid strength, proton affinity and host–guest interactions

Brønsted acids mediate chemical transformations via proton transfer to bound species and interactions between the conjugate anion and bound cationic intermediates and transition states that are also stabilized by van der Waals forces within voids of molecular dimensions in inorganic hosts. This Feature Article describes the relevant descriptors of reactivity in terms of the properties of acids and molecules that determine their ability to donate and accept protons and to reorganize their respective charges to optimize their interactions at bound states. The deprotonation energy (DPE) of the acids and the protonation energy (Eprot) of the gaseous analogs of bound intermediates and transition states reflect their respective properties as species present at non-interacting distances. These properties accurately describe the reactivity of acids of a given type, such as polyoxometalates (POM) with a given type of addenda atom but different central atoms and heterosilicates, for different families of reactions. They do not fully capture, however, differences among acid types (e.g., Mo and W POM, heterosilicates, mineral acids) for diverse types of chemical transformations (e.g., elimination, isomerization, dimerization, condensation). The incompleteness of such descriptors reflects their inability to describe how protonated molecular species and conjugate anions restructure their respective charges when present as a binding pair at interacting distances. Such interaction energies represent electrostatic forces that depend on charge distributions in the cations and anions and the ability to reorganize the distributions to maximize the interactions. In the case of deprotonation, the electrostatic and charge reorganization components of DPE for various acids solely reflect the ability of the conjugate anion to accept and distribute the negative charge, a characteristic unique of each type of solid acid and specifically of the composition of its extended conjugate anion framework. The energy required to accept and rearrange the positive charge in bound intermediates and transition states reflects, in turn, their respective ability to recover the ionic and covalent components of DPE, the energy required to detach proton from conjugate anions. The DPE components and the recovery fractions together lead to a modified DPE, which captures only the part of DPE that remains unrecovered by the ion-pair interactions at bound intermediates and transition states, as the unifying descriptor for broad families of acids and reactions. The electrostatic and charge reorganization energies involved in these general descriptors are placed in historical context by assessing their connections to the heuristics of hard–soft acid–base displacements. Further development of these concepts requires benchmarking and extension of electrostatic and reorganization components of energies for a more diverse set of reaction types and acid families and advancement of methods for more efficient calculations of electrostatic interactions. Reactivity descriptors must also account for dispersive interactions between host cavities and guest molecules, requiring a framework analogous to the one described here for ion-pair interactions; these dispersive interactions depend on the fit between their shapes and sizes as well as their ‘‘structural stiffness’’ that determines the ability to modify the shapes of molecules and voids to minimize free energy. Entropy considerations and estimates of their dependence on properties of catalysts and molecules are also required for accurately determining Gibbs free energies that ultimately determine reaction rates.

Deshlahra, Prashant↗
DOE OSTI2015

Development of a detachable high speed miniature scanning probe microscope for large area substrates inspection

We have developed a high speed, miniature scanning probe microscope (MSPM) integrated with a Positioning Unit (PU) for accurately positioning the MSPM on a large substrate. This combination enables simultaneous, parallel operation of many units on a large sample for high throughput measurements. The size of the MSPM is 19 × 45 × 70 mm{sup 3}. It contains a one-dimensional flexure stage with counter-balanced actuation for vertical scanning with a bandwidth of 50 kHz and a z-travel range of more than 2 μm. This stage is mechanically decoupled from the rest of the MSPM by suspending it on specific dynamically determined points. The motion of the probe, which is mounted on top of the flexure stage is measured by a very compact optical beam deflection (OBD). Thermal noise spectrum measurements of short cantilevers show a bandwidth of 2 MHz and a noise of less than 15 fm/Hz{sup 1/2}. A fast approach and engagement of the probe to the substrate surface have been achieved by integrating a small stepper actuator and direct monitoring of the cantilever response to the approaching surface. The PU has the same width as the MSPM, 45 mm and can position the MSPM to a pre-chosen position within an area of 275×30 mm{sup 2} to within 100 nm accuracy within a few seconds. During scanning, the MSPM is detached from the PU which is essential to eliminate mechanical vibration and drift from the relatively low-resonance frequency and low-stiffness structure of the PU. Although the specific implementation of the MSPM we describe here has been developed as an atomic force microscope, the general architecture is applicable to any form of SPM. This high speed MSPM is now being used in a parallel SPM architecture for inspection and metrology of large samples such as semiconductor wafers and masks.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Displacement driven balancing of a diamond turning machine flycutter

The spindle balancing operation is critical to the performance of precision lathes and should be conducted anytime the configuration of the spindle or its tooling is modified such that an unbalanced condition may occur. Within the machine tool community, accelerometers are typically used as the feedback device during the balancing operation. At Lawrence Livermore National Laboratory (LLNL), we have nearly 40 years of history using displacement sensors, such as capacitance gauges, in place of accelerometers when balancing precision spindles. The process of balancing a precision machine spindle using displacement sensors is presented in the context of two work examples. In this case, the details of the one-dimensional balancing operation performed after replacing a flycutter on the spindles of two unique large optic diamond turning machines is discussed. The pros and cons of accelerometer driven balancing and displacement driven balancing are also presented. In the accelerometer context, the level of balance achieved for our work example is less than 100 micro-g or a total indicator reading (TIR) of 1.6 µm. The process of balancing has been enhanced over the years as advances have been made in software, data acquisition systems, and instrumentation. The balancing system is described including details about instrumentation, set-up, how phase and spindle structure stiffness is calculated, and how the LLNL developed software that guides the user through the process by suggesting corrective action.

42 ENGINEERING↗
DOE OSTI2022

A New Perspective of Post-Weld Baking Effect on Al-Steel Resistance Spot Weld Properties through Machine Learning and Finite Element Modeling

The root cause of post-weld baking on the mechanical performance of Al-steel dissimilar resistance spot welds (RSWs) has been determined by machine learning (ML) and finite element modeling (FEM) in this study. A deep neural network (DNN) model was constructed to associate the spot weld performance with the joint attributes, stacking materials, and other conditions, using a comprehensive experimental dataset. The DNN model positively identified that the post-weld baking reduces the joint performance, and the extent of degradation depends on the thickness of stacking materials. A three-dimensional finite element (FE) model was then used to investigate the root cause and the mechanism of the baking effect. It revealed that the formation of high thermal stresses during baking, from the mismatch of thermal expansion between steel and Al alloy, causes damage and cracking of the brittle intermetallic compound (IMC) formed at the interface of the weld nugget during welding. This in turn reduces the joint performance by promoting undesirable interfacial fracture when the welds were subjected to externally applied loads. The FEM model further revealed that increase in structural stiffness, because of increase in steel sheet thickness, reduces the thermal stresses at the interface caused by the thermal expansion mismatch and consequently lessens the detrimental effect of post-weld baking on the joint performance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry

Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.

Additive manufacturing↗
DOE OSTI2017

Stiffness optimization of non-linear elastic structures

Our paper revisits stiffness optimization of non-linear elastic structures. Due to the non-linearity, several possible stiffness measures can be identified and in this work conventional compliance, i.e. secant stiffness designs are compared to tangent stiffness designs. The optimization problem is solved by the method of moving asymptotes and the sensitivities are calculated using the adjoint method. And for the tangent cost function it is shown that although the objective involves the third derivative of the strain energy an efficient formulation for calculating the sensitivity can be obtained. Loss of convergence due to large deformations in void regions is addressed by using a fictitious strain energy such that small strain linear elasticity is approached in the void regions. We formulate a well-posed topology optimization problem by using restriction which is achieved via a Helmholtz type filter. The numerical examples provided show that for low load levels, the designs obtained from the different stiffness measures coincide whereas for large deformations significant differences are observed.

42 ENGINEERING↗
DOE OSTI2022

Parked aeroelastic field rotor response for a 20% scaled demonstrator of a 13‐MW downwind turbine

Abstract Aeroelastic parked testing of a unique downwind two‐bladed subscale rotor was completed to characterize the response of an extreme‐scale 13‐MW turbine in high‐wind parked conditions. A 20% geometric scaling was used resulting in scaled 20‐m‐long blades, whose structural and stiffness properties were designed using aeroelastic scaling to replicate the nondimensional structural aeroelastic deflections and dynamics that would occur for a lightweight, downwind 13‐MW rotor. The subscale rotor was mounted and field tested on the two‐bladed Controls Advanced Research Turbine (CART2) at the National Renewable Energy Laboratory's Flatiron Campus (NREL FC). The parked testing of these highly flexible blades included both pitch‐to‐run and pitch‐to‐feather configurations with the blades in the horizontal braked orientation. The collected experimental data includes the unsteady flapwise root bending moments and tip deflections as a function of inflow wind conditions. The bending moments are based on strain gauges located in the root section, whereas the tip deflections are captured by a video camera on the hub of the turbine pointed toward the tip of the blade. The experimental results are compared against computational predictions generated by FAST, a wind turbine simulation software, for the subscale and full‐scale models with consistent unsteady wind fields. FAST reasonably predicted the bending moments and deflections of the experimental data in terms of both the mean and standard deviations. These results demonstrate the efficacy of the first such aeroelastically scaled turbine test and demonstrate that a highly flexible lightweight downwind coned rotor can be designed to withstand extreme loads in parked conditions.

17 WIND ENERGY↗
DOE OSTI2019

Simplified 2D Skin Lattice Models for Multi-Axial Camber Morphing Wing Aircraft

Conventional fixed wing aircraft require a selection of certain thickness of skin material that guarantees structural strength for aerodynamic loadings in various flight modes. However, skin structures of morphing wings are expected to be flexible as well as stiff to structural and coupled aerodynamic loadings from geometry change. Many works in the design of skin structures for morphing wings consider only geometric compliance. Among many morphing classifications, we consider camber rate change as airfoil morphing that changes its rate of the airfoil that induces warping, twisting, and bending in multi-axial directions, which makes compliant skin design for morphing a challenging task. It is desired to design a 3D skin structure for a morphing wing; however, it is a computationally challenging task in the design stage to optimize the design parameters. Therefore, it is of interest to establish the structure design process in rapid approaches. As a first step, the main theme of this study is to numerically validate and suggest simplified 2D plate models that fully represents multi-axial 3D camber morphing. In addition to that, the authors show the usage of lattice structures for the 2D plate models’ skin that will lead to on-demand design of advanced structure through the modification of selected structure.

Alsaidi, Bashir↗