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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 OSTI2022

Initial Development of Variable Design Lifetimes and Creep-Fatigue Evaluations for ASME Section III, Division 5, Class B Code Rules

This report summarizes the initial development of new ASME Section III, Division 5, Class B rules to address the gaps identified for new high temperature reactor designs. The overall objective is to introduce the design-by-analysis approach, the variable design lifetimes for primary load design, and the strain limits and creep-fatigue damage evaluations for Class B components. It is also desired that the new evaluation procedures do not require stress classification and stress linearization. Further, the data requirements to support the development of design parameters for the new Class B rules would not be overly burdensome, and less extensive than those supporting Class A rules. We have identified the Elastic, Perfectly Plastic (EPP) method as the design by-analysis approach for primary load design, and developed allowable stress criteria for variable design lifetimes, up to 500,000 hours, that only require data typical for the allowable stresses in Section II, Part D, Tables 1A and 1B. We have also adapted the elastic analysis approach from HBB-T-1400 and Section III, Mandatory Appendix XIII, XIII-2400 and XIII-3520(e) for the new Class B creep-fatigue evaluation procedure. A new elastic follow-up-based Isochronous Stress Strain Curve (ISSC) stress relaxation procedure has been developed to provide adequate conservatism commensurate with Class B constructions. No stress classification and stress linearization are required in the new procedure. Future work needed to complete the development is also summarized.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Interim Development of new Class B Code Case with Variable Design Lifetime and enhanced design rules to guard against cyclic structural failure mode

This report summarizes updates on the ongoing development of the new American Society of Mechanical Engineers Section III, Division 5, Class B rules to address the potential failure modes of Class B components. An initial design-by-analysis approach and supporting design rules are presented. The elastic-perfectly plastic (EPP) analysis approach has been adopted for primary stress limit and ratcheting check to prevent the component failure against the structural failure mode against primary load and strain accumulation due to cyclic loads. The creep-fatigue damage assessment uses explicitly defined elastic follow-up calculated from the stress concentration region of given component. Damage fraction calculation uses a novel coupled approach to capture the influence of the elastic follow-up and provide adequate conservatism for Class B components. The proposed Class B rules does not use the stress classification approach and uses the combined loads to assess component.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Descriptor Aided Bayesian Optimization for Many-Level Qualitative Variables With Materials Design Applications

Abstract Engineering design often involves qualitative and quantitative design variables, which requires systematic methods for the exploration of these mixed-variable design spaces. Expensive simulation techniques, such as those required to evaluate optimization objectives in materials design applications, constitute the main portion of the cost of the design process and underline the need for efficient search strategies—Bayesian optimization (BO) being one of the most widely adopted. Although recent developments in mixed-variable Bayesian optimization have shown promise, the effects of dimensionality of qualitative variables have not been well studied. High-dimensional qualitative variables, i.e., with many levels, impose a large design cost as they typically require a larger dataset to quantify the effect of each level on the optimization objective. We address this challenge by leveraging domain knowledge about underlying physical descriptors, which embody the physics of the underlying physical phenomena, to infer the effect of unobserved levels that have not been sampled yet. We show that physical descriptors can be intuitively embedded into the latent variable Gaussian process approach—a mixed-variable GP modeling technique—and used to selectively explore levels of qualitative variables in the Bayesian optimization framework. This physics-informed approach is particularly useful when one or more qualitative variables are high dimensional (many-level) and the modeling dataset is small, containing observations for only a subset of levels. Through a combination of mathematical test functions and materials design applications, our method is shown to be robust to certain types of incomplete domain knowledge and significantly reduces the design cost for problems with high-dimensional qualitative variables.

Engineering↗
DOE OSTI2023

Rotor and wake aerodynamic analysis of the Hybrid-Lambda concept - an offshore low-specific-rating rotor concept

The low-specific-rating rotor concept Hybrid-Lambda introduces a blade design with nonuniform distribution of design variables (design tip speed ratio and axial induction) along the blade span to alleviate loads of the outboard section in strong winds. In this paper, we validate aerodynamic design calculations, which were carried out with the blade element momentum theory by comparing the results to free vortex wake investigations (FVW). Furthermore, we investigate the wake behaviour with FVW and large-eddy simulations. The results show good agreements between the blade element momentum theory and FVW for integrated rotor quantities (power and thrust). Small deviations are present when the gradients of axial induction along the span are large. The wake of the Hybrid-Lambda Rotor shows advantages in the near-wake region (up to 4 diameters [D] downstream), especially in the outer wake annulus and in low turbulence scenarios. For further downstream positions, the wake is comparable to that of the reference turbine.

17 WIND ENERGY↗
DOE OSTI2024

Accelerating the design of lattice structures using machine learning

Lattices remain an attractive class of structures due to their design versatility; however, rapidly designing lattice structures with tailored or optimal mechanical properties remains a significant challenge. With each added design variable, the design space quickly becomes intractable. To address this challenge, research efforts have sought to combine computational approaches with machine learning (ML)-based approaches to reduce the computational cost of the design process and accelerate mechanical design. While these efforts have made substantial progress, significant challenges remain in (1) building and interpreting the ML-based surrogate models and (2) iteratively and efficiently curating training datasets for optimization tasks. Here, we address the first challenge by combining ML-based surrogate modeling and Shapley additive explanation (SHAP) analysis to interpret the impact of each design variable. We find that our ML-based surrogate models achieve excellent prediction capabilities (R 2 > 0.95) and SHAP values aid in uncovering design variables influencing performance. We address the second challenge by utilizing active learning-based methods, such as Bayesian optimization, to explore the design space and report a 5 × reduction in simulations relative to grid-based search. Collectively, these results underscore the value of building intelligent design systems that leverage ML-based methods for uncovering key design variables and accelerating design.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Numerical Optimization of Spray-Guided Spark Assistance for Cold Idle Operation in a Heavy-Duty Gasoline Compression Ignition Engine

This article describes the results of a response surface model (RSM)-based numerical optimization campaign for spray-guided spark assistance at cold operations in a heavy-duty gasoline compression ignition (GCI) engine. On the basis of an earlier work on spark-assisted GCI cold combustion, a space-filling design of experiments (DoE) method was first undertaken to investigate a multitude of hardware design variables and engine operating parameters. The main design variables included the number of injector nozzles, fuel split quantities and injection timings, and spark timing. The objective variables were engine combustion efficiency (ŋ c ), maximum pressure rise rate (MPRR), and engine-out nitrogen oxide (NO x ) emissions. A total of 150 design candidates were automatically generated using the Sobol sequence method provided by the commercial software package, CAESES. Then, closed-cycle computational fluid dynamic (CFD) spark-assisted GCI simulations under cold idling operations were performed. The outcomes from the CFD-DoE design campaign were utilized to construct high-fidelity RSMs that allowed for further design optimization of the spark plug- and fuel injector-related design variables, along with fuel injection strategy parameters. A merit function with respect to objective variables was formulated with an appropriate weight assignment on each objective variable. Finally, the best design candidate was identified from the RSM-based optimization process and further validated in the CFD analysis. The best design candidate showed the potential to significantly improve combustion efficiency (ŋ c > 90%) over the baseline at cold idle while satisfying MPRR and NOx emissions constraints (MPRR < 5 bar/CAD and NO x < 4.5 g/kWh).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Optimal design of acoustic metamaterial cloaks under uncertainty

In this work, we consider the problem of optimal design of an acoustic cloak under uncertainty and develop scalable approximation and optimization methods to solve this problem. The design variable is taken as an infinite-dimensional spatially-varying field that represents the material property, while an additive infinite-dimensional random field represents the variability of the material property or the manufacturing error. Discretization of this optimal design problem results in high-dimensional design variables and uncertain parameters. To solve this problem, we develop a computational approach based on a Taylor approximation and an approximate Newton method for optimization, which is based on a Hessian derived at the mean of the random field. We show our approach is scalable with respect to the dimension of both the design variables and uncertain parameters, in the sense that the necessary number of acoustic wave propagations is essentially independent of these dimensions, for numerical experiments with up to one million design variables and half a million uncertain parameters. Additionally, we demonstrate that, using our computational approach, an optimal design of the acoustic cloak that is robust to material uncertainty is achieved in a tractable manner. The optimal design under uncertainty problem is posed and solved for the classical circular obstacle surrounded by a ring-shaped cloaking region, subjected to both a single-direction single-frequency incident wave and multiple-direction multiple-frequency incident waves. Finally, we apply the method to a deterministic large-scale optimal cloaking problem with complex geometry, to demonstrate that the approximate Newton method’s Hessian computation is viable for large, complex problems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Objective and algorithm considerations when optimizing the number and placement of turbines in a wind power plant

Abstract. Optimizing turbine layout is a challenging problem that has been extensively researched in the literature. However, optimizing the number of turbines within a given boundary has not been studied as extensively and is a difficult problem because it introduces discrete design variables and a discontinuous design space. An essential step in performing wind power plant layout optimization is to define the objective function, or value, that is used to express what is valuable to a wind power plant developer, such as annual energy production, cost of energy, or profit. In this paper, we demonstrate the importance of selecting the appropriate objective function when optimizing a wind power plant in a land-constrained site. We optimized several different wind power plants with different wind resources and boundary sizes. Results show that the optimal number of turbines varies drastically depending on the objective function. For a simple, one-dimensional, land-based scenario, we found that a wind power plant optimized for minimal cost of energy produced just 72 % of the profit compared to the wind power plant optimized for maximum profit, which corresponded to a loss of about USD 2 million each year. This paper also compares the performance of several different optimization algorithms, including a novel repeated-sweep algorithm that we developed. We found that the performance of each algorithm depended on the number of design variables in the problem as well as the objective function.

17 WIND ENERGY↗
DOE OSTI2025

A Dual-Mode Hybrid System Combining Solar Thermal With Pumped Thermal Energy Storage

A hybrid system that delivers renewable electricity generation and electricity storage capabilities is introduced. This dual-mode hybrid system is based on Pumped Thermal Energy Storage (PTES) which uses a heat pump to convert electricity into thermal energy that is trans-ferred to silica particles which are stored in concrete silos. The stored heat is later converted back to electricity in a heat engine. The heat pump and heat engine use a closed Joule-Brayton cycle and fluidized bed heat exchangers. If the PTES system is co-located with an array of concentrating solar mirrors and a particle receiver, then the silica particles may also be heated up by the concentrating solar power (CSP) system. The PTES heat engine may also be used to convert the stored solar heat into electricity, thereby sharing this system between the PTES and CSP systems and reducing costs. However, this requires careful management of the heat engine off-design parameters. A thermodynamic model is used to evaluate the performance of the dual mode PTES-CSP hybrid system. The model accounts for turbomachinery effi-ciency, and approach temperature and pressure loss in heat exchangers, as well as other sources of inefficiency, such as motor-generator losses, and air fan power. The hybrid system also requires the evaluation of the turbomachinery efficiency and pressure ratio at off-design conditions since the CSP system operates over different temperature ratios than the Carnot Battery. Several design variables and design modifications are investigated, such as pressure ratios and maximum temperatures.

14 SOLAR ENERGY↗
DOE OSTI2022

Multi-Pressure Rail System Design with Variable Pressure Control Strategy

This paper presents the design and the control method of a Multiple Pressure Rail system (MPR) with a variable pressure control logic that allows minimization of throttling loss, therefore, increasing the overall fluid power actuation efficiency. An MPR system allows controlling hydraulic actuators with a pressure control logic, as opposed to traditional flow control logics which are well established in mobile applications. A proper setting of the number of pressure rails and the pressure level in each rail permits optimizing the system efficiency of an MPR solution. MPR systems have been recently proposed with different purposes, but seldom adopt variable pressure control strategies to manage the pressure variations in the rails. Moreover, the related past work attempts to maximize the energy recovery during overrunning load conditions. This paper, instead, addresses the case of an MPR system that handles a multitude of hydraulic functions without significant overrunning loads, as it occurs in many mobile applications such as in agriculture. The paper first presents the design alternatives considered for the MPR system, including the supply, the control valves, and the controller. Second, a dedicated test rig is developed to support experimental activities and validations of a lumped parameter model developed within this research to develop the MPR control strategy. The results describe the operating features of the proposed MPR solution. By considering the case of a traditional LS system, the paper results also show how system efficiency can be highly improved, with energy savings in the order of 49%

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Moving the needle: Employing deep reinforcement learning to push the boundaries of coarse-grained vaccine models

Highly mutable infectious disease pathogens (hm-IDPs) such as HIV and influenza evolve faster than the human immune system can contain them, allowing them to circumvent traditional vaccination approaches and causing over one million deaths annually. Agent-based models can be used to simulate the complex interactions that occur between immune cells and hm-IDP-like proteins (antigens) during affinity maturation—the process by which antibodies evolve. Compared to existing experimental approaches, agent-based models offer a safe, low-cost, and rapid route to study the immune response to vaccines spanning a wide range of design variables. However, the highly stochastic nature of affinity maturation and vast sequence space of hm-IDPs render brute force searches intractable for exploring all pertinent vaccine design variables and the subset of immunization protocols encompassed therein. To address this challenge, we employed deep reinforcement learning to drive a recently developed agent-based model of affinity maturation to focus sampling on immunization protocols with greater potential to improve the chosen metrics of protection, namely the broadly neutralizing antibody (bnAb) titers or fraction of bnAbs produced. Using this approach, we were able to coarse-grain a wide range of vaccine design variables and explore the relevant design space. Our work offers new testable insights into how vaccines should be formulated to maximize protective immune responses to hm-IDPs and how they can be minimally tailored to account for major sources of heterogeneity in human immune responses and various socioeconomic factors. Our results indicate that the first 3 to 5 immunizations, depending on the metric of protection, should be specially tailored to achieve a robust protective immune response, but that beyond this point further immunizations require only subtle changes in formulation to sustain a durable bnAb response.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

42 ENGINEERING↗
DOE OSTI2025

Parallel derivative-free optimization for simulation-based design of behind-the-meter energy systems

In this work, the integrated design and dispatch of behind-the-meter or distributed resources (e.g. stationary battery storage and solar PV generation) is considered. A simulation-based framework is employed, generating high-fidelity results with closed-loop predictive control at a fine resolution, at the expense of high computational cost (several minutes to a few hours per design point). To address this challenge, parallel derivative-free design methods are considered. Four methods are compared, including state-of-the-art surrogate-based methods (Radial-Basis Functions and Gaussian processes) and sampling strategies, an evolutionary-based method, and a simple sequential grid refinement method. As a case study, two types of design problem with increasing complexity are considered, namely, the design of behind-the-meter resources (three design variables) and the inclusion of grid capacity (four design variables). The second yields a constrained design problem for which violations can only be determined after solving the computationally expensive simulation. For the three-dimensional case, all methods present a good performance, achieving a solution within 1% of the optimum after the first iteration, with the sequential grid refinement exhibiting the fastest convergence and achieving the best final objective value. This indicates that the parallel evaluation of multiple sampling points may be more important than the choice of method for small decision spaces. For the four-dimensional constrained case, the Genetic Algorithm presents the best tradeoff between performance and computational effort, while the rough objective function terrain generated by constraint violation penalties reduces the performance of surrogate-based methods. Contour plots with flat regions indicate flexibility in the optimal design and highlight the importance of characterizing the solution space.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2021

High-level fuel fabrication facility designs from discrete-event simulation

Like other industrial processes, the production of metallic nuclear fuels (MNF) requires that fabrication facilities be able to reliably meet production demands, operate efficiently, and adhere to federal and local safety regulations. In turn, the set of design variables employed by such a facility, such as operations policies, infrastructure and machinery purchased, and the type and number of staff hired, directly impact a facility’s ability to satisfy these goals. Therefore, facility designers must carefully determine which set of design variable values optimally satisfies these constraints. In this paper, we explore how values for these high-level design variables, namely hiring requirements, can be determined in the context of nuclear fuel manufacturing through the coupling of physics-based and discrete-event simulation technologies. Using the Versatile Test Reactor (VTR) program as a case study, we demonstrate how SCALE and MCNP nuclear physics model outputs can be integrated into ExtendSim discrete-event simulation (DES) models of the fuel fabrication process to determine the optimal number of staff hired to ensure fuel production goals are met, operations comply with effective dose limit regulations, and overall project costs are reduced.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Identifying Entangled Physics Relationships Through Sparse Matrix Decomposition to Inform Plasma Fusion Design

We report a sustainable burn platform through inertial confinement fusion (ICF) has been an ongoing challenge for over 50 years. Mitigating engineering limitations and improving the current design involves an understanding of the complex coupling of physical processes. While sophisticated simulation codes are used to model ICF implosions, these tools contain necessary numerical approximation but miss physical processes that limit predictive capability. Identification of relationships between controllable design inputs to ICF experiments and measurable outcomes (e.g., neutron yield, neutron velocity, areal density) from performed experiments can help guide the future design of experiments and development of simulation codes, to potentially improve the accuracy of the computational models used to simulate ICF experiments. We use sparse matrix decomposition methods to identify clusters of a few related design variables. Sparse principal component analysis (SPCA) identifies groupings that are related to the physical origin of the variables (laser, hohlraum, and capsule). A variable importance analysis finds that in addition to variables highly correlated with neutron yield, such as picket power and laser energy, variables that represent a dramatic change of the ICF design, such as number of pulse steps, are also very important. The obtained sparse components are then used to train a random forest (RF) regression surrogate for predicting total yield. The RF performance on the training and testing data compares with the performance of the RF trained using all the design variables considered. This work is intended to inform design changes in future ICF experiments by augmenting the expert intuition and simulation results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗