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At least 181 records · Page 10

Synergy of tensile strength and high cycle fatigue properties in a novel additively manufactured Al-Ni-Ti-Zr alloy with a heterogeneous microstructure

Alloy design strategies in additive manufacturing (AM) to achieve grain refinement and terminal eutectic solidification have been introduced to engineer Al alloys having microstructural hierarchy and heterogeneity. Such alloy design strategies enable crack-free builds with an expanded AM processing window and pushed the strength limit in Al alloys. However, fatigue performance of Al alloys made by AM is restricted by the presence of process induced defects and its stochasticity. In this work, tensile and high cycle fatigue (HCF) behavior of a novel Al-Ni-Ti-Zr alloy with a heterogeneous microstructure is studied in the as-built condition, supplemented by detailed microstructural and mechanical characterization. Excellent strength-ductility synergy of 342 MPa and 16% failure strain achieved in the alloy was associated with the microstructural attributes that pertain to the novel alloy. Additionally, the alloy showed excellent HCF performance with a fatigue endurance limit to ultimate tensile strength ratio of 0.29 in flexural fatigue mode. The study revealed the existence of multiple crack retardation mechanisms and favorable crack propagation pathways through the fine-grained regions which enabled good fatigue performance to the alloy. Further, a probabilistic model has been used to estimate the fatigue life of the alloy as a function of the stochastic microstructure by utilizing the statistical distribution of pores, solid-state inclusions, and grains in the AM Al alloy. Finally, the model parametric trends are consistent with the experimental observations.

36 MATERIALS SCIENCE↗

Performance and economic viability assessment of a novel CO 2 adsorbent for manufacturing and integration with coal power plants

Here, this study assesses the performance and economic feasibility of a novel CO 2 adsorbent for post-combustion capture in DOE/NETL’s 650 MWnet SubC PC power plant (case B11B). Bench-scale tests showed an initial adsorption capacity of 16.3 wt%, which decreased to 12.1 wt% after 41 adsorption–desorption cycles due to induced particle aggregation by over-humidification. With a conservative adsorption capacity of 8.8 wt% and 695 adsorption–desorption cycles, an adsorbent replenishment rate of 10 tonnes/h is necessary to capture 90% of CO 2 . The breakeven sale price of the adsorbent produced at this rate is $\$$1,293/tonne, which is 40 to 80 times lower than prices for K 2 CO 3 adsorbents reported in the literature (e.g., K 2 CO 3 /TiO 2 , K 2 CO 3 /ZrO 2 ) while providing better capture performances. Sensitivity analysis reveals that increasing the plant production rate from 10 to 40 tonnes/h reduces the sale price by 8%. The study also compares the CO 2 capture cost to Cansolv, an integrated solvent-based technology. The novel adsorbent requires 2.4 GJ/tonne of CO 2 for regeneration, lower than Cansolv’s 2.7 GJ/tonne. With conservative performance estimates, the capture cost is $\$$54/tonne of CO 2 , slightly higher than Cansolv’s $\$$45/tonne. To achieve lower or comparable capture costs to Cansolv, the adsorbent should meet one of the following conditions at a commercial scale: minimum 950 cycles, 16 wt% capture capacity, 50% of the adsorbent recovery, or a reduced cost to $\$$646/tonne by upscaling the manufactury to 75 tonnes/h.

01 COAL, LIGNITE, AND PEAT↗

GeoMicro3D: A novel numerical model for simulating the reaction process and microstructure formation of alkali-activated slag

Highlights: • The GeoMicro3D model was innovatively developed for simulating the reaction process and microstructure formation of AAS. • In GeoMicro3D, the dissolution of slag and reactions of aqueous ions are fundamentally described in the local lattice cell. • A novel approach is proposed to speed up the nucleation simulations. • GeoMicro3D was implemented and verified with the relevant experimental data and thermodynamic calculation results. For the first time, this study developed a novel model, named GeoMicro3D, to simulate the reaction process and microstructure formation of alkali-activated slag. The GeoMicro3D model consists of four modules that are designed to simulate, respectively: (i) the initial spatial distribution of real-shape slag particles in alkaline activator, (ii) the dissolution of slag and diffusion of ions via the transition state theory and lattice Boltzmann method, respectively, (iii) the spatial distribution of reaction products using a nucleation probability theory, and (iv) the chemical reactions with thermodynamic modelling. Afterwards the GeoMicro3D model was implemented and verified. The simulation results were discussed and compared with the relevant experimental data and thermodynamic calculation results using GEMS. A good agreement was found in the comparisons, showing the strong simulation capability of GeoMicro3D.

36 MATERIALS SCIENCE↗

Novel structured Sm 0.5 Sr 0.5 CoO 3-δ cathode for intermediate and low temperature solid oxide fuel cells

The performance of solid oxide fuel cell (SOFC) can be significantly enhanced using nanostructured cathode obtained by infiltration/impregnation method. However, this method has been limited due to multi-step preparation process and instability of the obtained nanoscale catalyst under long-term operation. We report here a simple, cost-effective and reproducible approach to fabricate nanostructured Sm 0.5 Sr 0.5 CoO 3-δ (SSC) cathode with enhanced performance and stability. The SSC powders were prepared by a freeze-drying method through a combustion route using Pluronic F-127 as the template. The SSC freeze-drying powders have unique morphology and a significant phase change at 750 °C. The oxygen non-stoichiometry (δ) of the SSC powders is 0.18 at room temperature, while the δ values are 0.66, 0.75 and 0.90 at 600 °C, 700 °C and 800 °C, respectively. The novel structured SSC cathode was prepared by screen-printing and one-step sintering process using the freeze-drying SSC powders. Maximum cell power densities of 0.83 and 1.13 W cm -2 are achieved at 550 °C and 600 °C, respectively for single cells with the novel structured SSC cathode. Moreover, single cells show excellent stability at 600 °C under a current density of 600 mA cm -2 over 250 h. This work expands opportunities to exploit nanotechnology in a wide range of intermediate and low temperature energy conversion devices.

25 ENERGY STORAGE↗

Enabling thermal energy storage in structural cementitious composites with a novel phase change material microcapsule featuring an inorganic shell and a bio-inspired silica coating

Phase change material (PCM) microcapsules offer a promising approach for integrating PCM into building materials for efficient thermal energy storage. Here, this study presents the development of a novel PCM microcapsule specifically designed for incorporation into cementitious materials. The microcapsule consists of a low-cost PCM core derived from vegetable oil by-products and a durable inorganic shell made from cenosphere, a hollow fly ash generated from coal burning power plants. A novel process is developed to apply a silica coating to these cenosphere-based PCM microcapsules (CPCM), resulting in bioinspired-silica-coated CPCM microcapsules (BCPCM). This coating process draws inspiration from marine microorganism-based silica production and utilizes low-cost sodium silicate as a precursor, enabling eco-friendly and cost-effective manufacturing at ambient temperature and mild pH conditions. The morphology, chemical stability, and thermal properties of the BCPCM along with its thermo-mechanical performance in cementitious composites were comprehensively analyzed. Experimental results demonstrate successful silica deposition on BCPCM, leading to enhanced latent heat properties of the produced BCPCM. With the silica coating, BCPCM exhibits a 50 °C delay in thermal decomposition compared to CPCM, enhancing fire resistance and preventing premature PCM leakage of the microcapsule. The bioinspired silica coating effectively restores over 10% of the strength loss for each percent increase in CPCM incorporated into the mortar. The thermal performance experiments reveal that increasing the BCPCM content reduces temperature peaks and rates of temperature increase, indicating an improved capacity for thermal energy storage. This new PCM microcapsule provides a cost-effective solution to integrate thermal energy storage to cementitious material, as evidenced that over 30% of aggregates (in volume) can be replaced by the microcapsule without a drastic loss of strength.

25 ENERGY STORAGE↗

Mathematical modeling of novel porous transport layer architectures for proton exchange membrane electrolysis cells

Thin foil based porous transport layers (PTLs) that contain highly structured pore arrays have shown promise as anode PTLs in proton exchange membrane electrolysis cells. These novel PTLs, fabricated with advanced manufacturing techniques, produce thin, tunable, multifunctional layers with reduced flow and interfacial resistances and high thermal and electric conductivities. To further optimize their design, it is important to understand their fundamental impact on the transport of protons, electrons, and liquid/vapor mixtures in the electrode. In this work, we develop a two-dimensional multiphysics model to simulate the coupled electrochemistry and multiphase transport in an electrolysis cell operated with the novel PTL architecture. The results show that larger pores improve access of water to the anode catalyst layer, which is beneficial for both the oxygen evolution reaction and membrane hydration. Larger pore sizes also improve oxygen gas transport from the catalyst layer, because generated oxygen gas is forced to travel in-plane through the anode catalyst layer until it reaches a pore opening that is connected to a channel. The discussed results confirm that the proposed thin foil based PTLs are fundamentally different from conventional PTLs, such as felts or layered meshes. The model developed in this work also provides generalizable insight into fundamental PEMEC phenomena, such as the competition between liquid and gas phase transport, membrane hydration and water management, and nonuniform electrochemical reactions, which are processes relevant to all PEMEC designs.

25 ENERGY STORAGE↗

The anode supported internal cathode tubular solid oxide fuel cell: Novel production of a cell geometry for combined heat and power applications

An effective strategy for generating combined heat and power (CHP) systems is to use the combustion of hydrocarbons to provide fuel reforming and heat production for solid oxide fuel cell (SOFC) operation. Though tubular SOFCs (tSOFCs) are well suited to the thermal cycling associated with combustion systems, they have a geometric limitation which requires significant alteration to the combustion chamber. These alterations can be eliminated by producing an anode supported internal cathode-tSOFC (IC-tSOFC) which can be directly integrated into the chamber with minimal alterations. Novel methods used to produce IC-tSOFCs are discussed in this work. Scanning electron microscopy (SEM) and performance characterization are used to analyze fabricated cells. Finally, with a peak power density of 369 mW∙cm –2 , and an open circuit voltage (OCV) of 0.98 V, it is confirmed that novel production methods for IC-tSOFCs have been successful.

08 HYDROGEN↗

Post-hazard condition assessment of nuclear piping-equipment systems: Novel approach to feature extraction and deep learning

Over the past decade, the use of artificial intelligence techniques in the field of health-monitoring has gained significant interest, especially for structures such as building and bridges. However, applications to industrial systems such as equipment-piping systems in nuclear plants have not been explored. Here, in this paper, it is shown that the existing techniques developed for buildings and bridges cannot be extended directly to equipment-piping systems as the response of such systems is governed by multiple localized modes unlike that in buildings and bridges. This paper proposes a new approach that consists of three key aspects: (i) a novel vector of degradation-sensitive features extracted from measured data, (ii) using a deep Artificial Neural Network (ANN) for diagnosis of degradation location and degradation severity, and (iii) consideration of uncertainty in degradation severity when training the ANN. Degradation in piping-equipment systems can occur due to flow-accelerated erosion and corrosion. These locations can potentially exhibit damage such as localized yielding or initiation of cracking due to an external event such as an earthquake. Moreover, such locations can at times go undetected by current inspection techniques. Therefore, a robust framework is needed for detection of degradation after a seismic event. This manuscript proposes a proof-of-concept framework, which utilizes data collected from sensors to generate a deep ANN database for predicting degraded locations and severity in a piping-equipment system. Degradation severity is classified as minor, moderate, and severe. In the suggested methodology, a novel vector of degradation-sensitive features is extracted from the sensor data to train the ANN. A simple piping-equipment system is selected to demonstrate feature extraction as a means to simplify pattern recognition, explore the design and parameters of an ANN, and develop a sensor placement strategy. The effectiveness of the proposed framework is demonstrated on a realistic primary safety system of a two-loop nuclear reactor. It is shown that the proposed post-hazard condition assessment framework is able to detect degraded locations along with the severity levels, including minor degradation, with considerably higher accuracy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Novel geometries for air-cooled condensation of ammonia-water mixtures

An analytical and experimental investigation of air-cooled condensers for small-scale ammonia-water absorption heat pumps is presented. Conventional round-tube corrugated fin design and a novel multi-pass tube array design are considered for a condenser operating at severe ambient conditions within a compact footprint. Segmental heat and mass transfer models are developed to gain a deeper understanding of the characteristics of each design. Predicted heat duties are within 5% of the measured values. The limitations of correlations to predict air-side pressure drop in corrugated fins are identified. The performance of the novel multi-pass tube array condenser was comparable to that of conventional condensers, but is determined to be air-side limited throughout length of the heat exchanger. An improved multi-pass condenser design with fins for increased air-side area is proposed using the insights gained from the modeling and experiments. In closing this design meets the heat duty requirements at severe ambient conditions, while decreasing the size of the heat exchanger by 33%.

42 ENGINEERING↗

Investigating the FLASH Effect in a Rat Brain Organotypic Model With a Novel High-Energy Electron Beam

Ultrahigh dose rate (FLASH) radiation therapy is reported to reduce normal tissue toxicity while maintaining tumor control; however, mechanism(s) remain obscure. To study FLASH mechanisms in brain tissue, we developed a novel experimental platform featuring a specialized high-energy electron linear accelerator, High Intensity Gamma Ray Source (HIGS), paired with an organotypic ex vivo brain metastasis model. We varied interpulse spacing to modulate the mean dose rate (MDR) of our unique 35 MeV electron beam, while maintaining extremely high instantaneous dose rate (IDR). We characterized dosimetry and targeting accuracy of the FLASH beam with film dosimetry. We combined this FLASH beam with an organotypic rat brain slice/breast carcinoma coculture model of brain metastasis to assess effects on normal and neoplastic tissues. Live-cell and bioluminescence imaging demonstrated cancer cell growth effects, whereas normal tissue responses and immune activation were assessed using live-cell imaging, cytokine profiles, and confocal microscopy. Here, we performed comparison experiments with 20 MeV electrons from a Varian clinical linear accelerator (VCLA) using conventional dose rates. The highest IDR of the FLASH beam to date was 20.7 ± 0.6 MGy/s, with maximum MDR of 20.7 MGy/s delivered in 1 pulse of 1 µs duration. Beam targeting was accurate to <1 mm and reproducible. HIGS-FLASH and VCLA dose rates equivalently decreased cancer cell growth. HIGS-FLASH irradiation significantly increased tumor necrosis factor α and fractalkine levels and confocal microscopy revealed distinct changes in microglial morphology slices suggesting microglia activation. Our novel experimental platform produces extremely high dose rates and rapid normal/neoplastic tissue readouts for mechanistic research into the effects of FLASH radiation in the brain. HIGS-FLASH irradiation induces comparable cancer cell growth inhibition but differential effects on cytokines and microglial morphology, suggesting that acute innate immune responses may be involved in FLASH normal tissue effects in the brain.

Kay, Tyler V. [Duke University, Durham, NC (United↗

Novel nonwetting solid-infused surfaces for superior fouling mitigation

Fouling is a ubiquitous issue in several environmental and energy applications. Here we introduce novel nonwetting solid-infused surfaces (SIS) with superior anti-fouling characteristics that are durable than conventional nonwetting surfaces in a dynamic flow environment. A systematic study is presented to elucidate the fouling mitigation performance of SIS in comparison to lubricant-infused surface (LIS) and conventional smooth surface. Copper tubes with SIS, LIS or smooth inner walls are fabricated and subjected to accelerated calcium sulfate fouling in a flow fouling experimental setup. Fouling on the various surface types is quantified in terms of asymptotic fouling resistance, and the fundamental morphological differences in the interactions of the foulant and the various surface types are analyzed. Based on a systematic sweep of the parameter combinations using design of experiments and Taguchi analysis, an analytical dependence of asymptotic fouling resistance on the governing parameters namely, Reynolds number, foulant concentration and temperature is derived. The analytical model is shown to predict the asymptotic fouling resistance to within 20% accuracy with a 95% confidence. In addition, for the first time, the effects of shear durability on the fouling mitigation performance of LIS vis-à-vis SIS are studied. It is shown that the novel nonwetting SIS offers a robust option for superior fouling mitigation over LIS in the long run.

42 ENGINEERING↗

A novel optical sensor for Pb 2+ detection based on in-situ formation of Ruddlesden-Popper phase (C 4 H 9 NH 3 ) 2 PbBr 4 perovskite

On account of the concentration sensitive photoluminescence (PL) property of the lead-based Ruddlesden-Popper (RP) phase perovskite material, a novel sensing mechanism for highly selective Pb 2+ detection based on the in-situ formation of highly emissive luminescence structure matrix (C 4 H 9 NH 3 ) 2 PbBr 4 has been demonstrated. The sensor exhibits high sensitivity and selectivity for detecting Pb 2+ in complex metal cations mixture solution. This research reports a novel type of sensor mechanism based on the in-situ formation of luminescent lead-based RP phase perovskite. Here, it paves the way for developing highly selective optical sensors for detecting heavy metal cations via their corresponding luminescence structure matrix.

36 MATERIALS SCIENCE↗

Excellent high cyclic fatigue properties of a novel ultrafine-grained medium entropy alloy

Fatigue is a major cause of failure and requires dedicated investigation to validate the integrity of potential structural materials. As high and medium entropy alloys (HEAs and MEAs) are garnering significant attention from scientific communities, it is important to test the structural integrity of these novel alloys in cyclic loading environment. This study analyzed both monotonic and cyclic loading properties of a novel medium entropy alloy (MEA) CoCr 1.3 Ni in the ultrafine-grained (UFG) and fine grain (FG) conditions. The UFG MEA performs better than the FG MEA during cyclic loading. Microstructural evolution after cyclic loading via electron back-scattered diffraction shows microstructural stability of both FG and UFG microstructures. Transmission electron microscopy suggests formation of stacking faults and fine-scale HCP transformation during cyclic loading.

36 MATERIALS SCIENCE↗

A custom high-stability pulse generator for the test of a novel in-situ magnetic sensor developed to detect radiation damage in undulators

High-performance analog-to-digital converters (ADC) have been widely applied in many areas of science. For instance, magnetic field measurements based on the Faraday’s induction law require high-precision voltmeters to measure induced voltages. In this study in the context of free-electron lasers technology, the Magnetic Measurements Team at SLAC National Accelerator Laboratory proposed a novel in-situ radiation damage detection system (RDDS) for detecting small field variations in undulators. The system measures the flux change in a flexible printed-circuit coil attached to the magnet array during the undulator gap movement. The gap movement changes the magnetic field, which induces a voltage signal in the coil that is measured and integrated with an ADC. Although the system is capable of detecting relative flux changes better than 100 ppm, drift in the ADC’s gain or offset can cause apparent changes in the relative flux. This paper describes the first attempt to developed a high-precision verification circuit to perform ADC testing in the framework of the novel RDDS. The circuit generates a reference voltage pulse with a voltage–time integral relative precision better than 50 ppm for a few hundreds of mVs — the typical order of magnitude measured with the RDDS. The circuit’s design combines a fast and precise switch with a low-noise voltage reference. Long-term measurements allowed statistical analysis and showed that averaging the voltage–time integral of ten pulses gives the required 50 ppm stability. Moreover, reproducibility tests confirmed that the circuit’s output is invariable under small power supply instabilities and equipment shutdown. Instruments and applications designed to quantify the magnetic field by integrating voltage signals may use the pulse generator proposed in this paper for verification purposes.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Novel data analysis method for obtaining better performance from a complex 3D-printed collimator

Additively manufactured scattered beam collimators are increasingly being employed to boost the sample to cell peak signal ratio in high pressure neutron diffraction studies because of manufacturing versatility and performance improvements. We study how the measured diffraction pattern is affected by the presence of a collimator downstream of the sample, and develop a novel protocol that provides more effective background rejection. This protocol takes into account critical performance-determinants that were identified in this study, namely: (i) effectively identifying the collimator pattern on the detector; (ii) understanding the dependence of this pattern on sample and cell composition; and (iii) accurately identifying and differentiating the different regions of the pattern on the detector based on the dependency of the cell or sample and finally (iv) resolving the intensities at regions of the detector where neutrons scattered from the sample are preferentially represented, in order to boost the sample to cell peak signal ratio. Application of this novel analysis protocol is shown to increase the collimator performance over the traditional method.

3D printing↗

Oscillating surge wave energy converter using a novel above-water power takeoff with belt-arc speed amplification

We investigate the performance of a novel power takeoff (PTO) featuring belt-arc speed amplification for oscillating surge wave energy converters (OSWECs), aiming to address the challenges of extremely low rotary speed and large torque under the low-frequency ocean wave excitations. The belt-arc design significantly increases the rotary speed of the generator, enabling generator downsizing and decreasing the powertrain friction losses. The design also allows for placing the generator above water, eliminating the need for high Ingress Protection ratings for the generator and powertrain, and potentially leading to substantial reductions in capital and maintenance costs. Using the linear potential wave theory, the dynamics of the integrated system are analyzed, and key parameters are identified. To validate the numerical analysis, a 1:10 scale model is designed, fabricated, and tested in a wave tank. Performance evaluations are conducted under regular and irregular wave conditions, with quantified effects of parameter tuning. The results reveal an optimal wave-to-electric efficiency of 48% under regular wave excitation and 20% under irregular excitation. Furthermore, these findings underscore the effectiveness of the proposed novel PTO design in addressing the challenges of low rotation speed and large torque inherent in OSWECs, demonstrating its ability to efficiently convert wave power into electricity.

16 TIDAL AND WAVE POWER↗

Bond valence sum analysis of pyrochlore oxides including the novel dielectric Te 6+ pyrochlores: A Bi M TeO 7-y ( A = Cd, Ca; M = Cr, Ga, Sc, In, Fe)

Bond valence sum analysis is a powerful tool used in evaluating and validating crystal structures; especially when those structures are complex in nature. The pyrochlore structure type is versatile in not only the unique bonding that it exhibits, but also in the properties that results from the structure. Here this paper aims to center the discussion of evaluating the pyrochlore structure using the bond valence sum method. In this study, novel quaternary pyrochlores with a general stoichiometry of ABiMTeO 7 (A = Cd, Ca; M = Cr, Ga, Sc, In, Fe) were synthesized and characterized for their structural, magnetic, and dielectric properties. Two representative compounds within this series of pyrochlores, BiCaFeTeO7 and BiCdFeTeO 7 , were structurally characterized utilizing a combination of high-resolution synchrotron X-ray diffraction and neutron diffraction revealing oxygen deficient pyrochlore systems which were off from the expected stoichiometry with respect to the M site. The A site of both pyrochlores were found to be moved off-center from the expected 16d site to the 96h displaced position at a magnitude of 0.25 Å and 0.22 Å for the Bi/Ca and Bi/Cd systems, respectively. These structures were evaluated using the bond valence sum method and compared with trends in the literature. The properties are also reported for the Bi/Ca system for the first time, showing relatively high dielectric constants with a low dielectric loss which are primarily independent of frequency and temperature. The magnetic measurements for the Bi/Ca system for the magnetic substitutions reveal a paramagnet and antiferromagnetic properties for the Fe and Cr analogs, respectively. The novel BiCaMTeO 7 quaternary pyrochlore system shows great promise as an emerging dielectric material.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Characterization and verification of a two-body wave energy converter with a novel power take-off

The lack of high efficient, predictable and reliable power take-off (PTO) systems limits developments of ocean wave energy technology. In this paper, a two-body self-reacting wave energy converter (WEC) with a novel PTO is designed, modelled and implemented for efficiency enhancement. A novel mechanical motion rectifier (MMR) using a ball screw mechanism and an enclosed gear set is integrated to improve the energy harvesting efficiency and reliability by rectifying the oscillatory wave motion into unidirectional rotation of the generator. Detailed design and dynamic modelling for the proposed WEC are presented. A prototype of the PTO is tested in a dry lab to characterize and refine the dynamic modelling. The characterized PTO model is combined with the WEC model to create an overall system model. A water tank test is conducted to verify the overall system dynamics, which proves the accuracy of the model and shows the advantages of the proposed WEC on efficiency and predictability. Following the method of how the WEC system is characterized, performance prediction of the proposed WEC with MMR PTO can be achieved with high accuracy.

16 TIDAL AND WAVE POWER↗