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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

The Role of Innovation in the Circularity of EV Lithium-Ion Batteries

This case study analysis highlights the role of innovations in EV battery design (cells, modules, and packs), reverse supply chain, and recycling processes in yielding value for the economics of recycling (and have the largest impact on the circularity of LIBs). Part of the assessment of value will be a semi-quantitative evaluation of the value of resilience in the rapidly evolving LIB market – i.e., there are a variety of risks that recyclers would face in making a financial commitment to a recycling facility including; the possibility that batteries would not be collected in sufficient quantities, the market for key constituents (e.g., cobalt) might decrease because of changes in battery chemistry, battery manufacturers may not be willing to pay as much for recycled material, etc. The analysis would be semi-quantitative in that two simple models would be used to assess 1. material flows using a previously developed excel-based reverse supply chain flows model, and 2. A LIB recycling process material and energy balance cost model that will be used to qualitatively assess the cost impacts of process innovations and changes in feed streams. Both sets of models are highly speculative in that they rely on a multitude of assumptions and input values (e.g., EV adoption rates) that vary widely in the literature. Additionally, the initial process flow diagrams and equipment lists for the recycling cost model are based on the Argonne EverBatt model, which is still under development. However, in combination with a critical review of the literature, economic modeling can yield valuable insights into the role of innovation in the circularity of LIBs and high-technology (“energy relevant”) products in general.

28 EE - Advanced Manufacturing Office (EE-5A)↗
NASA NTRS1991

A unified approach for composite cost reporting and prediction in the ACT program

The Structures Technology Program Office (STPO) at NASA Langley Research Center has held two workshops with representatives from the commercial airframe companies to establish a plan for development of a standard cost reporting format and a cost prediction tool for conceptual and preliminary designers. This paper reviews the findings of the workshop representatives with a plan for implementation of their recommendations. The recommendations of the cost tracking and reporting committee will be implemented by reinstituting the collection of composite part fabrication data in a format similar to the DoD/NASA Structural Composites Fabrication Guide. The process of data collection will be automated by taking advantage of current technology with user friendly computer interfaces and electronic data transmission. Development of a conceptual and preliminary designers' cost prediction model will be initiated. The model will provide a technically sound method for evaluating the relative cost of different composite structural designs, fabrication processes, and assembly methods that can be compared to equivalent metallic parts or assemblies. The feasibility of developing cost prediction software in a modular form for interfacing with state of the art preliminary design tools and computer aided design (CAD) programs is assessed.

Freeman, W. Tom↗
DOE OSTI2025

Influence of extreme temperature conditions on CO 2 direct air capture using amino-acid solutions

Geological features play a pivotal role in determining the feasibility of deploying CO₂ direct air capture (DAC) technologies, primarily because they influence the availability of cost-effective energy sources, such as natural gas and geothermal energy, and also due to the potential for CO₂ sequestration. Many regions face challenges due to variable weather conditions including seasonal temperature fluctuations, high or low humidity, and sub-ambient temperatures. These extremes can reduce DAC performance or even lead to catastrophic events. Aqueous solvents considered for DAC systems are particularly vulnerable to seasonal variations in colder climates, where the solvent may underperform or freeze. It is therefore essential to investigate the CO₂ capture efficiency of aqueous solvents across a broad range of environmental temperatures, spanning sub-zero to hot conditions (>30 °C). In this study, DAC operation is examined using a high-flux solvent–air crossflow contactor under two major weather scenarios: (i) cold conditions below 0 °C and (ii) hot conditions above 30 °C. A parametric study is conducted to investigate the contactor performance regarding CO₂ removal efficiency, uptake capacity, and reaction kinetics versus temperature when the air velocity through the contactor exceeds 1 m/s. The efficacy of the contactor is systematically investigated using various anti-freeze amino-acid solvent formulations. A mass-transfer mechanistic model is developed to assess the process performance over a wide temperature range and propose scalable design guidelines. Machine learning is also employed to identify key parameters affecting the CO₂ capture efficiency. It is shown that air velocity and temperature are the primary factors influencing CO₂ uptake. Based on performance data obtained under subfreezing temperatures, a technoeconomic analysis is conducted to evaluate the feasibility of using aqueous solvents in seasonal cold regions. In conclusion, the findings of this study provide valuable insights into siting considerations for deploying solvent-based DAC, thereby contributing to the advancement of sustainable carbon removal solutions.

Air–liquid contactor↗
NASA NTRS2002

Natural and Induced Environment in Low Earth Orbit

The long-term exposure of astronauts on the developing International Space Station (ISS) requires an accurate knowledge of the internal exposure environment for human risk assessment and other onboard processes. The natural environment is moderated by the solar wind which varies over the solar cycle. The neutron environment within the Shuttle in low Earth orbit has two sources. A time dependent model for the ambient environment is used to evaluate the natural and induced environment. The induced neutron environment is evaluated using measurements on STS-31 and STS-36 near the 1990 solar maximum.

Wilson, John W.↗
NASA NTRS2008

Development of NASA's Models and Simulations Standard

From the Space Shuttle Columbia Accident Investigation, there were several NASA-wide actions that were initiated. One of these actions was to develop a standard for development, documentation, and operation of Models and Simulations. Over the course of two-and-a-half years, a team of NASA engineers, representing nine of the ten NASA Centers developed a Models and Simulation Standard to address this action. The standard consists of two parts. The first is the traditional requirements section addressing programmatics, development, documentation, verification, validation, and the reporting of results from both the M&S analysis and the examination of compliance with this standard. The second part is a scale for evaluating the credibility of model and simulation results using levels of merit associated with 8 key factors. This paper provides an historical account of the challenges faced by and the processes used in this committee-based development effort. This account provides insights into how other agencies might approach similar developments. Furthermore, we discuss some specific applications of models and simulations used to assess the impact of this standard on future model and simulation activities.

simulation↗
NASA NTRS2009

Ultrasonic Phased Array Simulations of Welded Components at NASA

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increasing role in the future for nondestructive evaluation in order to better understand the physics of the inspection process, to prove or disprove the feasibility for an inspection method or inspection scenario, for inspection optimization, for better understanding of experimental results, and for assessment of probability of detection. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles. Keywords: nondestructive evaluation, computational simulation, ultrasonics, weld, modeling, phased array

Roth, D. J.↗
DOE OSTI2020

BioSTEAMDevelopmentGroup/thermosteam

BioSTEAM is a fast and flexible package for the design, simulation, and techno-economic analysis of biorefineries under uncertainty. BioSTEAM’s framework is built to streamline and automate early-stage technology evaluations and to enable rigorous sensitivity and uncertainty analyses. Complete biorefinery configurations are available at the Bioindustrial-Park GitHub repository, BioSTEAM’s premier repository for biorefinery models and results. The long-term growth and maintenance of BioSTEAM is supported through both community-led development and the research institutions invested in BioSTEAM. Through the open-source and community-lead platform, BioSTEAM aims to foster communication and transparency within the biorefinery research community for an integrated effort to expedite the evaluation of candidate biofuels and bioproducts. Additionally, an agile life cycle assessment (LCA) platform has been designed to interface with BioSTEAM, BioSTEAM-LCA. This open-source, installable package allows users to perform streamlined LCAs of biorefineries. The focus of BioSTEAM-LCA is to streamline and automate early-stage environmental impact analyses of processes and technologies, and to enable rigorous sensitivity and uncertainty analyses linking process design, performance, economics, and environmental impacts. ThermoSTEAM is a standalone thermodynamic engine capable of estimating mixture properties, solving thermodynamic phase equilibria, and modeling stoichiometric reactions. ThermoSTEAM builds upon chemicals, the chemical properties component of the Chemical Engineering Design Library, with a robust and flexible framework that facilitates the creation of property packages. The Biorefinery Simulation and Techno-Economic Analysis Modules (BioSTEAM) is dependent on ThermoSTEAM for the simulation of unit operations.

Cortes-Peña, Yoel↗
NASA NTRS2018

Challenges in Development of Online Visualization and Analysis Tools for Satellite Data

Over the years, various online visualization and analysis tools have been developed to facilitate satellite data access and help scientific users around the world to conduct research and develop applications (e.g., data product evaluation, what-if questions, etc.). For those who are new to satellite data products, using them can be a daunting task due to many obstacles in data processing such as data formats, complex data structures, special software packages, unfamiliar terminology, etc., especially when one is not sure whether a dataset is suitable for his/er research project. Even for experienced users, developing software for data processing and analysis can be a costly and time-consuming task. Online visualization tools can overcome many of these difficulties and allow users to focus on scientific questions. For example, Giovanni (the Geospatial Interactive Online Visualization and Analysis Infrastructure, https://giovanni.gsfc.nasa.gov), developed by the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC), allows access over 1900 satellite and model variables in 82 measurement groups of 8 disciplines without downloading data and software. Main features include basic functions for data analysis and visualization, data provenance, output data in different formats (ASCII, NetCDF, GeoTIFF), and more. Over the years, ~1700 peer-reviewed publications in different disciplines have been benefited from Giovanni in research activities (e.g. initial investigation, what-if questions, product evaluation). Despite the success of online visualization and analysis tools, challenges and new opportunities still exist and more can be done with new requirements and technology. Examples are: a) how to increase the efficiency of dataset search by enhancing intuitive aspects; b) how to facilitate interdisciplinary research; c) how to provide data quality information; d) how to engage users to participate in data quality assessment; and more. NASA Earth Observing System Data and Information System (EOSDIS) satellite-based data products are processed at various levels ranging from Level 0 to Level 4. While most users use data products at higher levels (Level-3 and 4), products at lower levels are still important for case studies, algorithm development, ground validation, etc. In this presentation, we will use Giovanni as an example to present and discuss challenges and near-future opportunities for satellite data online visualization and analysis tools.

Liu, Zhong↗
DOE OSTI2023

Machine Learning Surrogates of a Fuel Matrix Degradation Process Model for Performance Assessment of a Nuclear Waste Repository

Spent nuclear fuel repository simulations are currently not able to incorporate detailed fuel matrix degradation (FMD) process models due to their computational cost, especially when large numbers of waste packages breach. The current paper uses machine learning to develop artificial neural network and k-nearest neighbor regression surrogate models that approximate the detailed FMD process model while being computationally much faster to evaluate. Further, using fuel cask temperature, dose rate, and the environmental concentrations of CO 3 2- , O 2 , Fe 2+ , and H 2 as inputs, these surrogates show good agreement with the FMD process model predictions of the UO 2 degradation rate for conditions within the range of the training data. A demonstration in a full-scale shale repository reference case simulation shows that the incorporation of the surrogate models captures local and temporal environmental effects on fuel degradation rates while retaining good computational efficiency.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2020

Defining Handling Qualities of Unmanned Aerial Systems: Phase II Final Report

Unmanned Air Systems (UAS) are no longer coming, they are here, and operators from first responders to Google and Amazon are demanding access to the National Airspace System (NAS) for a wide variety of missions. This includes a proliferation of small UAS or sUAS that will operate beyond line of sight at altitudes of 500 ft and below. A myriad of issues continues to slow the development of verification, validation, and certification methods that will enable the safe introduction of UAS to the NAS. These issues include the lack of both a consensus in UAS categorization process and quantitative certification requirements, including the definition of handling qualities. Because of the wide variety of UAS types (fixed wing, rotary wing from traditional helicopters to multirotor configurations, ducted fans, airships, etc.) and vehicle size from micro vehicles to the Global Hawk with a wing span similar to that of a Boeing 737, there cannot be a one-size-fits-all set of requirements. To address these issues, Systems Technology Inc. (STI) has developed the UAS Handling Qualities Assessment (UAS-HQ) process and corresponding draft specification that will guide UAS stakeholders through a systematic evaluation process. The work described herein builds on the existing, highly successful, military rotorcraft handling qualities specifications that features a mission-oriented approach, a concept that originated at STI. The vehicle is first identified by a simple weight-based classification and then the associated vehicle mission task elements are considered. These missions have specific tasks inclusive to them that then dictate the criteria and demonstration maneuvers necessary to evaluate the UAS handling qualities. An assessment of both modeled responses and flight test data can then be conducted to examine the predicted versus actual handling qualities and, if required, design modifications can then be made. Mr. David Klyde, Vice President and Technical Director, Engineering Services, served as Principal Investigator, while Dr. Natalia Alexandrov served as the NASA LaRC technical representative. In the Phase II program, STI was joined by David Mitchell of Mitchell Aerospace Research and the University of Minnesota. Mr. Mitchell led the draft specification development effort, while the University of Minnesota UAV Lab conducted sUAS flight tests under the direction of Dr. Peter Seiler.

Klyde, David H.↗
NASA NTRS2004

Assessment and Control of Spacecraft Charging Risks on the International Space Station

The International Space Station (ISS) operates in the F2 region of Earth's ionosphere, orbiting at altitudes ranging from 350 to 450 km at an inclination of 51.6 degrees. The relatively dense, cool F2 ionospheric plasma suppresses surface charging processes much of the time, and the flux of relativistic electrons is low enough to preclude deep dielectric charging processes. The most important spacecraft charging processes in the ISS orbital environment are: 1) ISS electrical power system interactions with the F2 plasma, 2) magnetic induction processes resulting from flight through the geomagnetic field and, 3) charging processes that result from interaction with auroral electrons at high latitude. Recently, the continuing review and evaluation of putative ISS charging hazards required by the ISS Program Office revealed that ISS charging could produce an electrical shock hazard to the ISS crew during extravehicular activity (EVA). ISS charging risks are being evaluated in an ongoing measurement and analysis campaign. The results of ISS charging measurements are combined with a recently developed model of ISS charging (the Plasma Interaction Model) and an exhaustive analysis of historical ionospheric variability data (ISS Ionospheric Specification) to evaluate ISS charging risks using Probabilistic Risk Assessment (PRA) methods. The PRA combines estimates of the frequency of occurrence and severity of the charging hazards with estimates of the reliability of various hazard controls systems, as required by NASA s safety and risk management programs, to enable design and selection of a hazard control approach that minimizes overall programmatic and personnel risk. The PRA provides a quantitative methodology for incorporating the results of the ISS charging measurement and analysis campaigns into the necessary hazard reports, EVA procedures, and ISS flight rules required for operating ISS in a safe and productive manner.

Koontz, Steve↗
DOE OSTI2024

A comprehensive numerical investigation on spray models for Direct-Injection Spark-Ignition engines

Gasoline direct-injection spark-ignition (DISI) engines generate a large portion of their unburned hydrocarbon (UHC) and soot emissions during the cold-start phase. A predictive computational fluid dynamics (CFD) modeling framework can be used to understand the physical processes that characterize fuel spray evolution and fuel-film formation at cold start conditions, which can help to reduce engine-out particulate emissions. This study systematically evaluated spray submodels and developed a set of simulation best practices for physical-numerical submodels with the goal of enabling accurate simulations of liquid spray behavior in a DISI engine. Three comprehensive experimental datasets containing free-spray projected liquid volume (PLV), liquid volume fraction (LVF), and near-field X-ray radiography data were used to validate the simulation results and evaluate the spray submodels. Systematic analysis delved into injected parcel distribution, droplet collision, spray breakup, and evaporation via a detailed assessment of the relevant spray submodels. Moreover, the effects of turbulence models and the initial turbulent flow properties on the liquid spray evolution were examined. Based on extensive calibration efforts, a set of simulation best practices for the free spray was developed and validated against the PLV/LVF data. Simulation results indicated that the uniform distribution for parcel initialization, coupled with appropriate droplet collision submodels, provides an improved spray morphology compared to the cluster distribution. The findings also underscored the importance of calibrating the Kelvin-Helmholtz Rayleigh-Taylor (KH-RT) breakup model constants and droplet heat transfer coefficient scaling factor to achieve favorable agreement regarding measured liquid penetration and spray widths. In conclusion, this study marks a substantial stride towards accurately predicting fuel film evolution and soot formation within DISI engine performance.

ECN Spray G↗
NASA NTRS1989

JPL reuse program

The goal of the JPL reuse activity is to develop a quantitative understanding of the factors which encourage or inhibit software reuse, and of productivity improvements achievable through reuse. The primary activity is the measurement of parameters relevant to reuse in the environment of actual projects. The program has three objectives: (1) to develop a model to allow assessment of competing reuse techniques, (2) to extend reuse from the unit to the sub-system level, and (3) to expand from specific applications to a broader application domain. Application domains, which apply to all interplanetary projects, include Mission Operations, Science Information Systems, Flight Software, and Simulations. The program is targeting all phases and activities of the life cycle and a full range of software products. The approach will be both experimental (observe, hypothesize and evaluate) and constructive (introduce new tools and techniques). The primary target projects are Deep Space Network activities - the Ground Facilities facility upgrade, the Network Operations Control Center upgrade, and the Signal Processing Center. This is the first group of closely related projects being done in Ada at JPL. A reuse base will be developed initially by classifying potentially reusable components from one project; it will be used and expanded with additional projects.

Brown, James W.↗
NASA NTRS2006

Evaluation of Mesoscale Model Phenomenological Verification Techniques

Forecasters at the Spaceflight Meteorology Group, 45th Weather Squadron, and National Weather Service in Melbourne, FL use mesoscale numerical weather prediction model output in creating their operational forecasts. These models aid in forecasting weather phenomena that could compromise the safety of launch, landing, and daily ground operations and must produce reasonable weather forecasts in order for their output to be useful in operations. Considering the importance of model forecasts to operations, their accuracy in forecasting critical weather phenomena must be verified to determine their usefulness. The currently-used traditional verification techniques involve an objective point-by-point comparison of model output and observations valid at the same time and location. The resulting statistics can unfairly penalize high-resolution models that make realistic forecasts of a certain phenomena, but are offset from the observations in small time and/or space increments. Manual subjective verification can provide a more valid representation of model performance, but is time-consuming and prone to personal biases. An objective technique that verifies specific meteorological phenomena, much in the way a human would in a subjective evaluation, would likely produce a more realistic assessment of model performance. Such techniques are being developed in the research community. The Applied Meteorology Unit (AMU) was tasked to conduct a literature search to identify phenomenological verification techniques being developed, determine if any are ready to use operationally, and outline the steps needed to implement any operationally-ready techniques into the Advanced Weather Information Processing System (AWIPS). The AMU conducted a search of all literature on the topic of phenomenological-based mesoscale model verification techniques and found 10 different techniques in various stages of development. Six of the techniques were developed to verify precipitation forecasts, one to verify sea breeze forecasts, and three were capable of verifying several phenomena. The AMU also determined the feasibility of transitioning each technique into operations and rated the operational capability of each technique on a subjective 1-10 scale: (1) 1 indicates that the technique is only in the initial stages of development, (2) 2-5 indicates that the technique is still undergoing modifications and is not ready for operations, (3) 6-8 indicates a higher probability of integrating the technique into AWIPS with code modifications, and (4) 9-10 indicates that the technique was created for AWIPS and is ready for implementation. Eight of the techniques were assigned a rating of 5 or below. The other two received ratings of 6 and 7, and none of the techniques a rating of 9-10. At the current time, there are no phenomenological model verification techniques ready for operational use. However, several of the techniques described in this report may become viable techniques in the future and should be monitored for updates in the literature. The desire to use a phenomenological verification technique is widespread in the modeling community, and it is likely that other techniques besides those described herein are being developed, but the work has not yet been published. Therefore, the AMIU recommends that the literature continue to be monitored for updates to the techniques described in this report and for new techniques being developed whose results have not yet been published. 111

Lambert, Winifred↗
DOE OSTI2024

Electrochemical Control for Corrosion in Molten Chlorides During CSP Plant Operation

The Liquid Pathway of the Concentrating Solar Power Generation 3 (CSP Gen3) program proposed low-cost molten chloride salt for energy storage. However, online corrosion control was identified as a remining major risk of the Liquid Pathway approach. This project addressed that risk. Electrochemical solutions for corrosion mitigation during CSP plant operation were investigated and their feasibility and scalability were evaluated. The leading cause of corrosion in molten chloride salt systems was identified as corrosive impurities that form within the salt upon exposure to trace amounts of air and moisture. Leveraging electrochemistry, reduction/oxidation reactions can be employed to remove these corrosive impurities. In Phase 1 of this project, a bench-scale batch electrochemical reactor was designed, fabricated, and used to assess the kinetics and thermodynamics of electrochemical salt purification. In Phase 2, a laboratory-scale flow reactor was designed, fabricated, and used to assess the efficacy of the electrochemical method under flowing conditions. Results show that under proposed operating conditions for the Liquid Pathway Gen3 Pilot Plant, the electrochemical method is significantly more effective at removing impurities than alternative chemical and thermal methods, and that the electrochemical method produces less harmful byproducts. A key advance made in the course of this project was the development of a 2-electrode method for electrochemical purification that is more scalable than previously developed 3 electrode methods. This novel method is based on Magnesium (Mg) electrowinning. A provisional patent based on this invention has been submitted (USPTO Application No. 63/480,355). Additional key advances made during this project include assessment of the effect of dissimilar alloys on corrosion, kinetic and thermodynamic evaluation of thermolysis reactions of impurities within the molten salt, characterization of byproducts of purification reactions, and generation of IP focused on isolating value-added products using molten salt-based electrochemistry that could be deployed to valorize the process (USPTO Application No. 63/478,806). Ultimately, this project represented a step toward feasibility of Liquid Pathway Gen3 CSP. The method developed under this project could significantly reduce capital expenses and operating costs and increase plant profitability by enabling use of less expensive alloys, decreasing maintenance, and increasing plant longevity. Key focus areas for follow-on work have been identified as 1) evaluation of the efficacy of the electrochemical method under turbulent conditions in a larger flow system, such as the FASTR loop, 2) development of methods for removal of purification byproducts, 3) modeling pilot and industrial scale performance of electrochemical salt purification during plant operation and 4) further assessment of the effect of impurities on salt vapor phase.

14 SOLAR ENERGY↗
DOE OSTI2025

Descriptor: High Temporal Resolution Meteorological Data at Oak Ridge Reservation (ORR-HiResMet)

Access to continuous, quality assessed meteorological data is critical for understanding the climatology and atmospheric dynamics of a region. Research facilities like Oak Ridge National Laboratory (ORNL) rely on such data to assess site-specific climatology, model potential emissions, establish safety baselines, and prepare for emergency scenarios. To meet these needs, on-site towers at ORNL collect meteorological data at 15-minute and hourly intervals. However, data measurements from meteorological towers are affected by sensor sensitivity, degradation, lightning strikes, power fluctuations, glitching, and sensor failures, all of which can affect data quality. To address these challenges, we conducted a comprehensive quality assessment and processing of five years of meteorological data collected from ORNL at 15-minute intervals, including measurements of temperature, pressure, humidity, wind, and solar radiation. The time series of each variable was pre-processed and gap-filled using established meteorological data collection and cleaning techniques, i.e., the time series were subjected to structural standardization, data integrity testing, automated and manual outlier detection, and gap-filling. The data product and highly generalizable processing workflow developed in Python Jupyter notebooks are publicly accessible online. As a key contribution of this study, the evaluated 5-year data will be used to train atmospheric dispersion models that simulate dispersion dynamics across the complex ridge-and-valley topography of the Oak Ridge Reservation in East Tennessee.

Steckler, Morgan R. [Oak Ridge National Laboratory↗
DOE OSTI2020

Complete Round-Robin Hydrogen Gas Analysis Capability Comparison (Milestone 2.6)

The Department of Energy (DOE) is currently evaluating strategies for the extended dry storage of aluminum-clad spent nuclear fuel (ASNF). Part of this assessment concerns the extent of radiolytic molecular hydrogen (H2) generation from the aluminum cladding’s oxyhydroxide corrosion layers. Understanding this radiation-induced process and the factors effecting it (e.g., system conditions such as temperature and gaseous environment) are essential for the development of predictive computer models to support the Technical Considerations and Challenges for Extended (> 50 yrs) Dry Storage of ASNF program. To achieve this goal and ensure that the experimental data gathered by Task 2 (Oxyhydroxide Layer Radiolytic Gas Generation Resolution) research groups (Idaho National Laboratory and Savannah River National Laboratory) are consistent, a round-robin H2 analysis capability comparison was initiated. Here we present the results from said round-robin and conclude that despite differences in sample preparation, irradiation parameters, and analytical procedures, the measured data are sufficiently consistent between the two laboratories (= 15%).

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2025

Fused Deposition Modeling Additive Manufacturing of Carbonized Structures via Waste-Enhanced Filaments

This report details the development, characterization, and use of coal-enhanced composite materials in additive manufacturing applications. High coal loading formulations—containing up to 70 wt.% coal—were successfully extruded and processed using commercially available 3D printers. Extensive experimental testing was conducted to assess the mechanical, thermal, and microstructural properties of the composites. In parallel, multi-scale computational modeling was employed to elucidate atomistic interactions and evaluate the effects of printing-induced defects on structural performance. Large-scale printability trials demonstrated the feasibility of fabricating complex components for tooling and construction applications, including wind turbine blade molds and modular wall sections. Techno-economic analyses demonstrated the cost-effectiveness and scalability of coal-enhanced composites for large-scale additive manufacturing applications such as wind turbine blade tooling.

01 COAL, LIGNITE, AND PEAT↗