Simulation of an Autonomous Surface Vehicle With Colocated Tidal Turbine
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16 TIDAL AND WAVE POWER↗
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Development of an Unmanned Mobile Current Turbine Platform: Preprint
The design and development of a prototype unmanned mobile floating platform, equipped with a custom low-flow marine current turbine for autonomously seeking and harnessing tidal/coastal currents is described. The platform is an unmanned surface vehicle in the form of a catamaran with two electric outboard motors and capabilities for autonomous navigation. An undershot water wheel, aided by a custom flow concentrator, has been selected as the basic design for the marine current turbine, which is mounted on the stern of the unmanned surface vehicle platform. The concept of operation is that the platform would navigate to a designated marine current resource, autonomously anchor at the location, align itself in the current and deploy the current turbine using a custom cable-lift deployment mechanism. As the turbine harnesses the local current, an onboard power-take-off device converts the harnessed mechanical energy to electricity which is stored in onboard batteries. Considerations of deployment in tidal and coastal waters required obtaining the necessary environmental permits for conducting in-water testing; developing required mitigation measures in protecting local wildlife and their habitats; and identifying potential in-water test sites and surveying them for their suitability in terms of the current resource, bottom type, water depth, and local boat traffic. The design and development of the turbine and the results of initial in-water testing are discussed. The potential for scaling up the system for extended capacity is presented.
ENGINEERING,TIDAL AND WAVE POWER↗
Final Technical Report - Autonomous Undersea and Surface Sailing Vehicles
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45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
Turboexpander for Direct Cooling in Hydrogen Vehicle Fueling Infrastructure
Hydrogen fuel cell electric vehicles (FCEVs) have been identified as one of a few options for zero carbon emissions transportation. A major advantage of FCEVs is that they can fuel quickly and follow a familiar fueling behavior to hydrocarbon-fueled vehicles. Whether light duty or heavy duty, the goal for a hydrogen dispenser is to fuel a vehicle in the same amount of time as the fossil fuel equivalent. When hydrogen is dispensed into the vehicle storage system, however, the temperature rises due to the Joule-Thomson effect and the heat of compression. Typically, vehicles store the compressed hydrogen in composite overwrapped pressure vessels that have a polymer liner with an operational temperature limit of 85°C. This temperature limit can be exceeded during fast fueling if hydrogen is not precooled. Precooling allows for a dispenser to fuel a vehicle at a faster flow rate by preventing the storage tank on the vehicle from overheating. Fueling protocols and requirements are presented in SAE J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles [1]. A heavy-duty equivalent is under development with similar requirements for precooling. Currently, conventional precooling for light-duty vehicle refueling uses a heat exchanger and chiller to cool the hydrogen gas to -40°C before entering the vehicle. The precooling system represents a significant part of the station capital and operating costs, so if the cost of the precooling system can be reduced by improving its efficiency, the overall station capital and operating cost can be reduced. In this project, National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) researchers teamed up to investigate the turboexpander precooling application. A turboexpander is a device that places a turbine in a flow path where a pressure differential can be attained. This expansion device will extract work and lower the temperature of the fluid as the pressure reduces. While initial calculations based on established principles showed potential for a turboexpander to generate cooled gas, much work needs to be done to prove the concept. Turboexpanders typically work best under steady state conditions, while the dispenser is a very dynamic flow system. Dynamic turboexpander systems have been proven, such as a turbocharger on a gasoline vehicle. The inlet pressure at a dispenser is also much higher than any other known turboexpander system but should behave similarly to higher density fluids at lower pressures. Having both performed initial calculations, NREL and SNL researchers teamed up to investigate the turboexpander precooling application further. A project was soon built around the idea with SNL performing system modeling using previously proven capabilities and NREL performing hardware characterization with established station capabilities. Creare LLC was contracted as the turbomachinery expert to design and build the concept device. Part way through the project, however, contracting issues with the funding partner caused the project to terminate early before building and characterizing the concept device. While the project could not continue, many key findings were already learned. This paper is a summary of those findings.
08 HYDROGEN↗
Low-Flow Marine Hydrokinetic Turbine for Small Autonomous Unmanned Mobile Recharge Stations
A prototype low-flow marine current turbine for deployment from a small unmanned mobile floating platform has been developed for autonomously seeking and harnessing tidal/coastal currents. The support platform is an unmanned surface vehicle (USV), in the form of a catamaran with two electric outboard motors and with capabilities for autonomous navigation. The USV utilized is a WAM-V 16 vehicle that has been developed separately with support from the Office of Naval Research (ONR) [1]. The marine current turbine is based on a freestream waterwheel (FSWW), also known as an undershot waterwheel (FSWW), mounted on the stern of the USV. The concept of operation involves the USV autonomously navigating to a designated marine current resource. Upon arrival, the USV anchors itself, aligns with the current, and deploys the FSWW turbine using a custom cable-lift mechanism. The turbine harnesses the local current, and an onboard power-take-off (PTO) device converts the mechanical energy into electricity, which is stored in an onboard battery bank. When energy harvesting is completed, the turbine and the anchor are retrieved and the USV navigates to a selected location. These unmanned at-sea platforms can provide power to other unmanned maritime systems. Specifically, in this project, the power generated onboard can be used to charge aerial drones via a custom flight deck that has been developed for the USV. The recharging capabilities offered by a fleet of such strategically placed recharging stations can significantly benefit aerial drones operating in the maritime domain by eliminating the need to travel back and forth to land or ship based charging stations. The project has resulted in the development of subcomponents, including the FSWW turbine, a novel PTO, an automated anchoring system for the USV, an automated turbine deployment system, and a flight deck with capabilities onboard the USV for landing, direct-contact charging and takeoff of aerial drones. The design and development of these subsystems have culminated in the overall prototype marine hydrokinetic platform (MHK Platform, Fig. 1). Comprehensive lab and field testing have been conducted to validate the functionality and performance of the platform and its components. The project demonstrates the potential for autonomous, unmanned systems to harness renewable energy from marine currents, and provide sustainable power solutions for maritime applications such as coastal surveillance and environmental monitoring; shoreline mapping; search and rescue; oceanographic research; inspection and maintenance of offshore energy installations like wind turbines and oil rigs; oil spill response; maritime disaster response; and aerial surveys, as well as facilitation of data transfer drones and shore stations.
16 TIDAL AND WAVE POWER↗
SMALL UNMANNED MARINE HYDROKINETIC PLATFORMS FOR POWER GENERATION IN COASTAL AND TIDAL WATERS
The feasibility and optimization of small unmanned mobile marine hydrokinetic (MHK) energy platforms for harvesting marine current energy in coastal and tidal waters are examined. A case study of a platform based on the use of a free-surface waterwheel (FSWW) mounted on an autonomous unmanned surface vehicle (USV) was conducted. Such platforms can serve as recharging stations for aerial drones (UAVs), enabling extension of the UAVs’ autonomous operating time. An unmanned MHK platform potentially meets this need with sustainable power harvested from water currents. For the case study, six different waterwheel configurations were field-tested in the Intracoastal Waterway of South Florida in support of determining the configuration that produced the most power. Required technologies for unmanned operations of the MHK platform were developed and tested. The data from the field-testing were analyzed to develop an empirical relation between the wheel’s theoretical hydrokinetic power produced and the mechanical power harnessed by the MHK platform with various waterwheel configurations during field-testing. The field data was also used to determine the electrical power generated by the FSWW configurations during field-testing. The study has led to the development of standardized testing procedures. The empirical relation is used to examine predicted power production through scaling up different physical aspects of the waterwheel.
McKinney, Adriana↗
An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles
This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.
ADVANCED PROPULSION SYSTEMS↗
Surface Properties of Double-Fin Generated Shock-Wave/Boundary-Layer Interactions
Shock-Wave/Boundary-Layer Interaction (SBLI) is ubiquitous in high-speed air vehicles. SBLI surface flowfield properties of crossing shocks induced by symmetric Double-Fins (DFs) at fin angles of 8° and 10° at Mach 2 are experimentally investigated; a 10° Single-Fin (SF) is also explored as a comparison. Surface visualization is used to capture distinct flowfield structures such as separation and upstream influence. Steady and unsteady Pressure-Sensitive Paints (PSPs) are used to obtain global surface pressure fields. Characteristics of DF-SBLI surface topology are discussed by comparing the corresponding SF-SBLI. Here, the effect of fin angle on DF-SBLI is characterized, and unsteady dynamics of the pressure field are examined. Spectral Proper Orthogonal Decomposition (SPOD) is performed on unsteady PSP, and traveling surface pressure waves and their frequency-dependent behavior are discussed. Dispersion relation of surface pressure waves is revealed by performing two-dimensional space–time Fourier transform on unsteady PSP, and the results are compared with the phase velocity distributions obtained from SPOD. Accompanying group velocity behavior is examined for distinct SBLI regions wherein wave propagation is found dependent on its frequency. Steady surface pressures along the centerline are compared with previous experimental data. Fin-tip spacing is found to be an essential parameter for scaling of upstream influence length.
33 ADVANCED PROPULSION SYSTEMS↗
A Three–Dimensional Nanoscale View of Electrocatalyst Degradation in Hydrogen Fuel Cells
The loss of platinum (Pt) electrochemically active surface area (ECSA) is a critical degradation mode that often becomes a limiting factor for heavy-duty proton exchange membrane fuel cell vehicles. High surface area carbon supports have been shown to improve Pt dispersion and limit detrimental ionomer-electrocatalyst interactions due to their large interior pore volume. Here, in this work, using automated scanning transmission electron tomography, the degradation of nanoparticles located on the interior versus exterior surfaces of the carbon support is compared following a catalyst-specific accelerated stress test (AST) of 90,000 voltage cycles between 0.6 V to 0.95 V. The results reveal a notable increase in median particle size for both interior and exterior Pt catalyst particles, with a slightly higher increase in particle size distribution and loss of specific surface area for the particles located on the exterior carbon surface. The fraction of Pt nanoparticles that reside within the interior of the carbon support also increased following the AST test, accompanied by evidence of an increase in average carbon mesopore size. Here, the results shed light on the degradation mechanisms affecting electrochemical properties and the enhanced particle accessibility at lower relative humidity.
08 HYDROGEN↗
Temperature Rise on Liner Surfaces of Fuel Cell Electric Vehicle Tanks during Fueling Process
Herein, the temperature of the inner tank walls, or plastic liners, of composite pressure tanks in fuel cell electric vehicles during fueling using three‐dimensional computational fluid dynamics (CFD) models is evaluated. The liner materials are limited to 85.0 °C to prevent thermal stress causing material failure that would result in a hydrogen leak. Therefore, the temperature of hydrogen gas must be limited to below 85.0 °C during the fueling process as dictated by the current fueling protocol. However, there are limited experimental or simulation data confirming that the temperature changes do not exceed the threshold. Herein, the liner temperatures with CFD tank models for two sizes of type IV tanks representative of the upper and lower system bounds that are close to the SAE J2601 fueling protocol (36.0 and 244.0 L) are evaluated. First, each model's reliability is validated with experimental data and then analyzed, and the data are used to evaluate the maximum hydrogen and liner temperatures under real‐world fueling conditions. The evaluation shows that the maximum liner surface temperature of each tank model is at least 7 °C lower than that of the hydrogen. Additionally, there is at least 12 °C difference found between the upper limit and actual liner temperatures.
33 ADVANCED PROPULSION SYSTEMS↗
Phased Construction Completion Report for Decontamination Laundry Demolition at the Oak Ridge National Laboratory
This Phased Construction Completion Report (PCCR) documents completion of demolition, waste disposition, and slab stabilization activities of Building 2523 (Decontamination Laundry) for the Oak Ridge National Laboratory (ORNL). The Decontamination Laundry is located directly north of the intersection of White Oak Avenue and the 2519 Access Road. This demolition scope included the removal of the above-grade structures and facility components associated with Building 2523. This scope included the removal of Building 2523 (and all remaining contents inside), Trailer 2523A (and all remaining contents inside), an above-grade wastewater tank, and a wooden access porch connecting Buildings 2523 and Trailer 2523A. On the north side of Building 2523, above-grade portions of selected remaining foundations/stairs were removed from former Building 2517 to make room to stage waste containers. Building 2621 is west of the Laundry Building and Buildings 2547 and 2649 are to the east, while Building 2525 is to the north. Building 2523 is located within Bethel Valley Exposure Unit (EU) 3. The total area of the EU is approximately 39 acres. The area within EU 3 is bounded by First Street on the west, Central Avenue on the north, Third Street on the east and south. The slab of Building 2523 has been stabilized with a cap of flowable fill concrete and asphalt to contain residual radiological contamination and to provide surface suitable for vehicle parking. No below-grade demolition actions were performed during this task.
99 GENERAL AND MISCELLANEOUS↗
Implementation of a High-Mach Integral Boundary Layer Method for Arbitrary Streamlined Body Geometry
The Momentum-Energy Integral Technique (MEIT) is an integral boundary layer method for the high-Mach flow regime used to approximate heat transfer and viscous force quantities of interest along streamlines of an inviscid flow solution on the surface of a flight vehicle. This method allows rapid mid-fidelity estimation of these quantities which would otherwise require a much more expensive viscous flow solution to produce. Integral boundary layer methods like MEIT have been around for decades, though usually only formulated for simple geometries such as 2-dimensional wing shapes or axi-symmetric nose shapes. The implementation discussed herein has been generalized to apply to any 3-dimensional streamlined body geometry through correct treatment of the curvilinear axes (streamline attached) momentum and energy entrainment terms, and handling of arbitrary stagnation region geometry. This implementation is provided as a software package for the Python environment, along with readers for common inviscid flow solution providers such as NASA’s CART3D flow solver.
97 MATHEMATICS AND COMPUTING↗
MODELING AND OPTIMIZATION OF A PCM-BASED OCEAN THERMAL ENERGY HARVESTER FOR POWERING UNMANNED UNDERWATER VEHICLES
As oceans cover over 70% of the planet’s surface, they represent a large reservoir of resources that remained vastly untapped. Uncrewed Underwater Vehicles (UUVs) are becoming key technology for ocean exploration. Ocean thermal gradient is a permanent and reliable energy source that can be used to power UUVs using phase change material (PCM)-based thermal engines. However, the main drawback of this technology is its low conversion efficiency. When using PCM-based thermal engines to power UUVs, there are different energy conversion stages, thermal-hydraulic, hydraulic-kinetic, kinetic-electrical, dependent of a wide variety of parameters. Thus, optimization of the overall energy conversion is still a challenge for powering the increasing energy demanding UUVs for long missions. The goal of this study is to propose a PCM-based ocean thermal energy harvesting system for powering the Solo II float. Using the ocean thermal energy reduces the cost for battery replacement and expands the float’s mission time. For this purpose, we developed a multiphysics model for a system consisting of thermal material, hydraulic, and electrical systems. This system is designed to provide the electrical power needed for the instruments aboard the underwater vehicle. The models of the hydraulic and the electric systems are implemented in MATLAB-Simulink/Simscape environment. The final model developed can provide 13.66 kJ of electrical energy, which is more than 1.5 times the energy requirement per cycle for the SOLO II float.
Ouro-Koura, Habilou↗
Outgassing behavior and heat treatment optimization of JSC-1A lunar regolith simulant
As NASA strives towards a long duration presence on the Moon, it has become increasingly important to learn how to better utilize resources from the lunar surface for everything from habitats, vehicle infrastructure, and chemical extraction. To that end, a variety of lunar simulants have been sourced from terrestrially available volcanic minerals and glass as Apollo regolith is unavailable for experimentation needing large masses. However, while mineralogy and chemical composition can approach that of lunar material in these simulants, there are still distinct non-lunar phases such as hydrates, carbonates, sulfates, and clays that can cause simulants to behave distinctly non-lunar in a variety of processing conditions that maybe applied in-situ to lunar material. Notably, severe glassy bubbling has been documented in a variety of vacuum sintering experiments on JSC-1A lunar mare simulant heated via microwaves. The origins of this outgassing have not been well understood but are normally attributed to the decomposition of non-lunar contaminates intrinsic to virtually all terrestrially sourced simulants. As such, a series of controlled environmental tests were performed to ascertain the origins of the high temperature outgassing and to develop heat treatments that can drive JSC-1A closer to lunar composition and behavior. It was found that in JSC-1A at elevated temperatures distinct gas evolutions of water, carbon dioxide, and sulfur dioxide occur in both inert gas and vacuum. Additionally, the presence of hydrogen during heat treatments was shown to dramatically change gas evolutions, leading to distinctly more lunar-like composition and behavior from JSC-1A simulant.
58 GEOSCIENCES↗
Payload concepts for investigations of electrostatic dust motion on the lunar surface
Significant experimental and computational investigations have explored the feasibility of electrostatically-motivated dust motion on the lunar surface. The motion of lunar dust influences our understanding of the evolution of the surface and may also present a hazard to future exploration vehicles and astronauts. The possibility of a sustained exploration presence on the lunar surface opens the door to long-term experiments on the lunar surface, akin to the science facilities on the International Space Station. We have identified four measurements/observations that would significantly advance our understanding of dust-plasma interactions on the lunar surface. In this context, we provide conceptual designs for payloads to obtain these observations: a Langmuir probe, dust deposit witness plate, regolith charge measurement instrument, and cameras to look for evidence of horizon glow. These payloads could deploy independently and sequentially, or together as a suite. The proposed payloads would provide key observations that would inform future modeling efforts and direct future in situ experiments to understand the dust-plasma environment, both for planetary science and spacecraft design applications.
42 ENGINEERING↗
Projection-based multifidelity linear regression for data-scarce applications
Surrogate modeling for systems with high-dimensional quantities of interest remains challenging, particularly when training data are costly to acquire. This work develops multifidelity methods for multiple-input multiple-output linear regression targeting data-limited applications with high-dimensional outputs. Multifidelity methods integrate many inexpensive low-fidelity model evaluations with limited, costly high-fidelity evaluations. We introduce two projection-based multifidelity linear regression approaches with linear and nonlinear features that leverage principal component basis vectors for dimensionality reduction and combine multifidelity data through: (i) a direct data augmentation using low-fidelity data, and (ii) a data augmentation incorporating explicit linear corrections between low-fidelity and high-fidelity data. The data augmentation approaches combine high-fidelity and low-fidelity data into a unified training set and train the linear regression model through weighted least squares with fidelity-specific weights. We introduce a proximity-based weighting scheme with automatic weight selection strategy through cross-validation. Here, the proposed multifidelity linear regression methods are demonstrated on approximating the surface pressure field of a hypersonic vehicle in flight and the temperature field on an aircraft disc braking system. In an ultra low-data regime of no more than twelve high-fidelity samples, multifidelity linear regression achieves approximately 2% – 12% improvement in median accuracy and a higher R 2 score relative to single-fidelity methods at comparable computational cost.
data augmentation↗
Mechanistic origins of corrosion protection of aluminum alloys by graphene/polyetherimide nanocomposite coatings
Light-weighting vehicular components through adoption of light-metal structural alloys holds promise for reducing the fuel consumption of internal combustion engine vehicles and increasing the range of battery electric vehicles. However, the alloyed microstructure and surface precipitates of aluminum alloys render these materials susceptible to corrosion under modest excursions from neutral pH. Traditional chromium-based anodic passivation layers are subject to increasingly stringent environmental regulations, whereas options for sacrificial cathodic films are sparse for electropositive metals. While hybrid nanocomposite coatings have shown initial promise, mechanistic underpinnings remain poorly understood. Here, a fully imidized polyetherimide (PEI) resin is utilized as the continuous phase with inclusion of unfunctionalized exfoliated graphite (UFG). A comprehensive investigation of the mechanisms of corrosion protection reveals key fundamental design principles underpinning corrosion inhibition. First, strong interfacial adhesion, which for PEI is facilitated by binding of imide carbonyl moieties to Lewis acidic sites on Al surfaces. Second, the miscibility of ion-impervious nanoscopic UFG fillers and stabilization of a substantial interphase region at UFG/PEI boundaries that result in minimizing the free volume at the filler/polymer interface. Finally, extended tortuosity of ion diffusion pathways imbued by the below-percolation-threshold 2D fillers. These three design principles help govern and modulate ion transport from electrolyte/coating interfaces to the coating/metal interface and are crucial for the extended preservation of barrier properties. The results suggest an approach to systematically activate multiple modes of corrosion inhibition through rational design of hybrid nanocomposite coatings across hard-to-abate sectors where light metal alloys are likely to play an increasingly prominent role.
36 MATERIALS SCIENCE↗
Mauka Energy FEVER Tool Dataset
Mauka Energy’s dataset, developed under the Forestry Electric Vehicle Energy Routing (FEVER) project and funded by the U.S. Department of Energy’s Small Business Innovation Research program, is a high-resolution geospatial resource designed to support energy modeling for electric log trucks in complex forestry environments. The dataset integrates detailed spatial and road network data to enable accurate simulation of vehicle performance across varied terrain. At its core, the dataset incorporates lidar-derived elevation models, road alignments, and surface classifications from Oregon State University’s McDonald-Dunn Research Forest. These data capture fine-scale variations in slope, curvature, and surface conditions across forest road systems, allowing for vehicle-level analysis of energy consumption and recovery. The dataset also includes data collected on the surrounding public and private road networks in Benton County, Oregon, used in real-world haul routes. These connecting segments provide critical context for modeling transitions between forest operations and regional transportation infrastructure, incorporating attributes such as grade profiles, elevation change, and speed constraints. This combined dataset underpins the development of Mauka Energy’s rolldown tool, which quantifies energy use and regenerative braking potential on downhill and variable-grade segments. By leveraging high-resolution terrain and road data, the FEVER project enables more accurate assessment of electric vehicle feasibility and performance in forestry applications.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗