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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Conceptual Fuel Element Design Candidates for Conversion of High Flux Isotope Reactor with Low-Enriched Uranium Silicide Dispersion Fuel

Engineering design studies are underway to assess the feasibility of converting the High Flux Isotope Reactor (HFIR) to operate with low-enriched uranium (LEU) silicide dispersion (U3Si2-Al) fuel. These studies are supported by the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. A systematic approach employing neutronic and thermal-hydraulic analyses have been performed with the ORNL Shift and HFIR Steady State Heat Transfer Code tools, respectively, to predict reactor performance and thermal safety margins for proposed LEU3Si2-Al fuel designs. The design process was initiated by generating an optimized design with fabrication features identified from previous studies that result in excellent performance and safety metrics. The approach continued by substituting a single fabrication feature anticipated to be difficult to manufacture with another feature expected to perform an analogous function to that of the removed feature. Four conceptual fuel element design candidates, with various fabrication features, for conversion of HFIR with 4.8 gU/cm3 LEU3Si2-Al fuel have been generated and shown to meet pre-defined performance and safety metrics. Results to date indicate that HFIR could convert with the subject fuel system and meet performance and safety requirements if, among other considerations, fabrication of the specific design features are demonstrated and qualification of the fuel is complete under HFIR-specific conditions.

Chandler, David↗
DOE OSTI2020

A 3D-printed molecular ferroelectric metamaterial

Significance Molecular ferroelectrics, which show the ability to switch the electromechanical activity by an external electric field, establish the basis for mechanical metamaterial technologies. Despite their theoretical promise, such mechanical metamaterials remain hindered by the lack of adaptive stimuli-responsive materials which can be effectively tuned “on demand” across time and length scales. Here, we unravel a printable mechanical metamaterial of imidazolium perchlorate with superior electromechanical coupling and reprogrammable stiffness. We propose a continuous rapid three-dimensional (3D) printing technique which can reduce the manufacturing time of ferroelectrics from hours down to minutes. The printed molecular ferroelectric metamaterial structure is then shown to enable a tunable-frequency vibration-isolating architecture. This study paves the way for rationally designed 3D-printable molecular ferroelectric metamaterials.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The Effect of a Carbon Fiber Layer Between the Cathode and the Current Collector on Battery Cell Performance

Contact resistance between the cathode active material (CAM) and the Al current collector can be reduced by applying carbon coatings to the Al current collector surface. However, this process requires an additional step of carbon layer coating on the current collector, which increases both manufacturing costs and processing time. In the present work, an interlayer of continuous unsized carbon fibers aligned in one direction (CF interlayer), is introduced between the Al current collector and the NMC811 cathode during cathode deposition on the Al current collector. This single-step approach eliminates the need for the additional carbon layer coating on the current collector. Additionally, this approach removes the use of toxic solvents and insulative polymers used for making the carbon coating. The CF interlayer improves the rate capability at higher C-rates. The CF interlayer lowers the contact resistance between the cathode particles and the current collector while improving the activation energy of charge transfer. The peel test showed that the CF interlayer does not affect the adhesion strength of the cathode layer with the current collector.

25 ENERGY STORAGE↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part 2

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. Here, a high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine. This paper defines a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute mixtures when properly matched to fuel spray characteristics, injection strategy, and a high-energy ignition system. Boost system layout and base engine architecture were selected to minimize parasitics and maximize after treatment effectiveness. A multi-cylinder engine was developed and calibrated over a steady-state map. Results fed vehicle simulations over the EPA city and highway test cycles to predict the fuel economy improvement and tailpipe emissions potential. Fuel economy improvements over the baseline vehicle were projected at 42% and 39% for active-urea and passive-ammonia SCR after treatment systems respectively. Controls complexity to achieve regulatory compliance and the cost of the lean after treatment system were identified as the primary challenges to commercial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part I

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio, and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. A high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the first to two papers describing the development of a combustion system combining lean-stratified combustion with Miller cycle for downsized boosted applications. The work was completed under a multi-year US DOE project. The goal was to define a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to highloads. Some of the unique challenges in synergistically combining the two concepts are highlighted in this paper. Here, a central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute (lean plus EGR) mixtures when properly matched to fuel spray characteristics, a multiple-injection strategy, and a high-energy ignition system. Other challenges specific to meeting exhaust emissions requirements with a high-efficiency engine are also explored in this study. In this Part 1 of the paper, the single-cylinder combustion system design, analysis, and testing is described. Multicylinder engine system design, analysis and development is described in Part 2 of the paper.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Air-to-Liquid Heat Exchanger Fabricated Using Deposition-Based Additive Manufacturing Processes

Abstract This work describes the use of deposition-based additive manufacturing (AM) techniques to fabricate air-cooled, two-fluid heat exchangers. The project focused on a Heating, Ventilation and Air Conditioning application and used an industry-standard copper/aluminum heat exchanger manufactured with conventional technology as the basis for assessing performance. The manufacturing constraints associated with using deposition-based AM technology for this application include the need for a continuous tool path within each build layer that allows uninterrupted extrusion and therefore defect-free water channel walls that correspond to a reliably leak-tight heat exchanger. A geometry that respects these constraints was developed, simulated, optimized and finally manufactured and tested. The material used was a composite of polymer filled with conductive flakes in order to provide high conductivity in the direction that heat must flow in this heat exchanger, across the wall separating the fluids. The measured performance for several test coupons matched the predicted performance and the test coupons exhibited performance that approach and in some cases exceeds conventional technology

Engineering↗
DOE OSTI2021

Sustainable Coal Tar Pitch Carbon Fiber Manufacturing

Coal is a versatile resource that has historically propelled the Industrial Revolution, transportation, and energy generation, and continues to meet needs for power. The United States possesses the largest worldwide coal reserves (with a 2019 total production-to-recoverable-reserves ratio of 0.05) that are of high quality and are cost-effective to recover (i.e., $0.03/kg–$0.10/kg). However, the demand of coal for power generation has declined because of a shift to natural gas (because of lower natural gas prices) and to renewable energy sources. This decline has affected the economic viability US coal industry. Historically, domestic demand for coal was driven mostly by the electric power sector, which accounts for about 93% of the total demand, followed by industrial uses (primarily for cement and chemicals at a minimal level) and steel production (coke). The complex, dense carbon chemical structure of coal, abundant domestic supply, and stable, low price gives it great potential for use in a wide range of value-added non-fuel coal products (e.g., nanomaterials at $20,000/kg–$100,000/kg and commercial-grade carbon fiber at $22/kg–$33/kg), as well as in upgraded coal fuels.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

5.5 Hybrid Additively Manufactured Tooling for Large Composite Structures

This program sought to lower tooling costs for tightly toleranced, large composite aerostructures by using large format additive manufacturing (LFAM). LFAM tooling has the potential to lower tooling costs, but the large and unpredictable thermal expansion of polymer-based tooling did not previously allow for the production of large structures made with high performance resins requiring 350 deg F cures. Geometric tolerance issues and demolding concerns continued to arise. The proposed approach for this work was to print a thin shell via additive manufacturing that would be used as a scaffold for a conventional tooling prepreg. The prepreg would be laminated and cured onto both sides of the shell, creating a tool with a sandwich construction. The cured prepreg would then be machined and serve as the tooling surface. In addition to providing a clean, pit-free surface, the prepreg stiffness and low thermal expansion would physically restrain the AM shell and prevent it from expanding during thermal cycling, thus preventing any geometric mismatch between the nominal and actual part dimensions. A stair-step approach was taken to prove out this approach. Coupon level testing was done to ensure a good bond was possible between the AM shell and the tooling prepreg. These samples were also used to determine the amount of prepreg needed to achieve the desired coefficient of thermal expansion (CTE). The project team than progressed to a subscale tool measuring two feet in length. The geometry used was a C-section spar from Airbus’ Wing of Tomorrow program. A hybrid tool, using the AM shell and tooling prepreg, was made, and a composite part was fabricated with the tool. Dimensional scans of the tool and part indicated that the desired CTE was achieved with the tool. A second tooling approach was taken to reduce risk. In this approach, a subscale tool of the same geometry as previously mentioned was created, but the tool was entirely constructed of the tooling prepreg. AM was used to print a “master” that was then used to fabricate the tool by creating a splash off of the master using tooling prepreg. The innovation was that the master was not machined, but rather, was used right off the printer after a small amount of surface preparation. Removing this machining step was thought to make this approach economically viable when compared to conventional master fabrication. As before, the tool was used to fabricate a part and tested for dimensional accuracy. For the conclusion of the program, a ten-foot tool was created using the hybrid tool approach. The geometry also came from the Airbus C-section spar previously mentioned. Some difficulty arose in accurately predicting the geometry of the tool after laminating the tooling prepreg, resulting in multiple material additions and a tool geometry change. A part was fabricated in an autoclave using the tool. A cost savings of almost 50% was achieved on the subscale tool in both the hybrid and master-style tool, but the savings dropped considerably as the tool length increased in the full-scale tool. Given the less than expected cost savings and added complexity of the tool construction, it is suggested that the master-style tool is best for immediate commercialization for larger tools (although it may be appropriate for smaller, table-top size tools). Since its construction is very similar to conventionally made composite tooling, there already exists a broad supply chain for building the tool, and project partner Additive Engineering Solutions (AES) is well acquainted with the design and build of the AM master needed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Q4FY20 Quarterly Report. LL20-AM-sensor

Tardigrade is an effort to create tunable thermal expansion materials for use in a ruggedized lens housing. This requires new computational algorithms to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. Project is 13 months into the 30 month on complete project plan. We are continuing effort on 3 main technical thrusts: algorithm development, multi-material additive manufacturing process exploration, and sensor/optics design and engineering. In FY20 we underspent the initial budget, partly due to work restrictions from Covid-19 pandemic, but are working to make up lost time

42 ENGINEERING↗
DOE OSTI2026

Evaluation of Hardware and Software Bill of Materials (HBOMs/SBOMs) Extraction Methods

Hardware and software bills of materials (HBOMs and SBOMs) provide important visibility into the components, dependencies, and supply chain relationships within programmable digital devices. This visibility is critical for advanced nuclear reactor applications, where use of common or shared hardware components, software libraries, suppliers, or manufacturing processes may create common cause failure (CCF) vulnerabilities despite apparent diversity. This paper evaluates current approaches for obtaining and analyzing HBOMs and SBOMs in support of CCF, diversity and defense-in-depth (D3) assessments, and begins to explore potential methods for artificial intelligence/machine learning-based analysis. The availability of BOM information from advanced reactor manufacturers and vendors, representative hardware and software categories found in advanced reactor systems continues to limit research [13]. This paper compares commonly used BOM formats, including CycloneDX, SPDX, and SWID. It also surveys publicly available tools for generating BOMs from source code, compiled binaries, and hardware-related information, noting limitations in language coverage, system age, and format interoperability. Finally, this paper evaluates methods for correlating BOM data with vulnerability and exploitability information, including VEX, CVE, and CWE resources. The findings indicate that publicly available nuclear-vendor BOMs are limited, making third-party extraction and research into novel analysis techniques necessary.

Cybersecurity↗
DOE OSTI2020

Batch and continuous methods for evaluating the physical and thermal properties of films

Thermal methods and systems are described for the batch and/or continuous monitoring of films and/or membranes and/or electrodes produced in large-scale manufacturing lines. Some of the methods described include providing an energy input into a film, measuring a thermal response of the film, and correlating these to one or more physical properties and/or characteristics of the film.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Demonstration and Validation of Additively Manufactured Intensified Device for Enhanced Carbon Capture

In FY 2018 and 2019, ORNL personnel designed, prototyped, characterized, and tested the enhancement of amine-based carbon capture using additively manufactured intensified devices, i.e., devices combining multiple thermodynamic and kinetic processes into one unit operation. State of the art scrubbing technology often employs inter-stage cooling which requires multiple stages of single-purpose unit operations, leading to larger equipment size, higher capital cost, and sometimes less than optimal operating conditions for each piece of equipment. It was proposed that integrating multiple thermodynamic and kinetic operations into one unit could mitigate or negate these drawbacks. Heat and mass transfer studies demonstrated that an additively manufactured intensified device could significantly improve capture efficiency at bench scale. This project is a continuation of FEAA130 and aims at (1) demonstration and validation of enhanced CO 2 capture with 3D printed intensified devices (i.e., mass exchanger packing with internal cooling channels), for low-aqueous-solvent (LAS) based capture at the ORNL-constructed laboratory-scale (4.5-feet tall) column, namely Column A, with built-in cooling and (2) computational scoping on the conceptual design of a flexible and modular larger column, namely Column B, at ORNL for further demonstration of enhanced capture for aqueous solvent. To execute this multi-faceted project scope, an integrated project team from ORNL’s Manufacturing Science Division is tasked with applying capabilities in computational fluid dynamics (CFD), additive manufacturing, and absorber-scale demonstration/validation experiments.

42 ENGINEERING↗
DOE OSTI2023

A Supply Chain Road Map for Offshore Wind Energy in the United States

"A Supply Chain Road Map for Offshore Wind Energy in the United States" identifies pathways to developing a domestic offshore wind supply chain that can manufacture and deploy the major components needed to set the United States on a pathway to installing 30 GW of offshore wind by 2030 and 110 GW by 2050. The report estimates that this supply chain could require an investment of at least $\$$22.7 billion this decade to meet an annual demand for components, ports, and vessels in 2030. Although this is a considerable investment, it could allow the industry to install around $\$$100 billion worth of offshore wind this decade by reducing risk of delays due to global supply chain bottlenecks and creating a robust network of assets that will continue to be effective well beyond 2030. The United States would need at least 34 manufacturing facilities employing 10,000 workers, 39,000 jobs in the supporting supply chain, 10 marshaling ports, 4-6 dedicated wind turbine installation vessels, 4-6 dedicated heavy-lift vessels, and 4-8 U.S.-flagged specialized feeder barges to come online this decade to support an average annual deployment of 4-6 gigawatts offshore wind capacity per year. This supply chain could be developed in 6-9 years, but would require near-term decision making and efficient permitting and planning to strategically develop these resources by 2030. Additional investment and expansion would be required in the 2030s as the sector expands into new regions (such as the Gulf of Mexico) and new technologies (such as larger wind turbines and floating wind energy projects). Furthermore, the planning process needs to meaningfully engage with communities that will be impacted by supply chain expansion to achieve just outcomes and maximize benefits to these stakeholders, which will result in a more equitable and sustainable supply chain. While U.S. offshore wind has made significant progress in recent years, remaining supply chain challenges include uncertainty surrounding deployment and procurement timelines; a lack of port and vessel infrastructure; and limitations in the available workforce, supporting supplier networks, and energy justice best practices. However, many of these problems can be addressed through improved communication between key stakeholder groups, support from federal and state governments, and forward-thinking designs of supply chain assets to accommodate future technology changes for fixed-bottom and floating offshore wind. Although it is a significant task, developing these domestic capabilities represents a once-in-a-generation opportunity to contribute to a decarbonized energy future and also create massive economic benefits that are distributed throughout the country.

17 WIND ENERGY↗
DOE OSTI2025

An assessment of the global cooling supply chain and implications for critical minerals

The global room air conditioner (AC) industry has undergone rapid growth, and the U.S. and India now face new supply chain risks due to China’s dominant role in manufacturing and driving demand. As India’s room AC market and related electricity consumption increases with continued economic development, it faces dual challenges of supply chain vulnerabilities and power grid blackouts from higher peak loads. To mitigate supply chain vulnerabilities for high-efficiency cooling equipment and critical mineral inputs to AC components, there is an increasing need to diversify the supply chain and address energy security and peak load risks to both the U.S. and India. This report assesses the potential for diversifying supply chains and scaling up manufacturing of highly efficient cooling equipment technologies and related critical mineral inputs in the U.S. and India. Successful cooperation on these technologies will enable the U.S., India, and their Quadrilateral Security Dialogue (Quad) partners to diversify AC supply chains while meeting India’s large and growing demand for efficient cooling. In the similarly concentrated supply chain for critical minerals, the U.S. and India can work with Japan and Australia to leverage each country’s strengths in diversifying mining, processing, and refining while pursuing alternatives to materials with high supply chain risks and supporting increased recycling and circular economy approaches.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Advanced High-Strength Steel - Basics and Applications in the Automotive Industry

Challenged to improve safety and fuel economy, automakers continually search for new materials to meet high standards. Several factors drive the material R&D and selection for automotive applications, including safety, fuel efficiency, environmentalism, manufacturability, durability, and quality. In the highly competitive automotive industry, cost is an extremely important factor in material selection. As the motivation to reduce the mass of vehicles continues to grow, automakers seek to maximize the efficiency of their materials selection. Materials in automotive applications are selected to minimize weight while meeting key criteria, including crash performance, stiffness, and forming requirements. Since the 1920s, steel has been the material of choice for automakers worldwide. The weight percentage of steel used in vehicles relative to other materials has grown from around 50% in the early 1980s to about 60% in 2010 for North American light vehicles. Today, steel makes up around 65% of an average automobile’s weight and is the backbone of the entire vehicle. On average, that is 900 kg of steel used per vehicle. To further enhance passenger safety, vehicle performance, and fuel efficiency, reducing the weight of vehicles has become one of the top priorities for the automotive industry. Advanced high-strength steels (AHSSs) are a new generation of steel grades that provide much higher strength and other advantageous properties than other materials while maintaining the high formability required for manufacturing. AHSSs help engineers meet requirements for safety, efficiency, emissions, manufacturability, durability, and quality at a low cost. The relevance of AHSSs is quickly increasing in the automotive industry, and AHSSs are the key material for vehicle mass reduction. Different types of AHSS help parts meet the varied performance demands in different areas of the vehicle, including both the crumple zone and passenger compartment.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Influence of Coating Method on the Performance of Roll-to-Roll Coated PEM Fuel Cell Catalyst Layers

As production of fuel cell vehicles and power systems increases there is a need to understand the process science of fuel cell manufacturing. Industrial production of polymer electrolyte membrane fuel cell (PEMFC) electrodes will rely on continuous roll-to-roll (R2R) coating methods to meet the rates needed for mass production. There are a variety of coating methods that could be used to coat catalyst layers. The different physics of each method may result in different morphologies and performance. Here we present the results of a study comparing fuel cell catalyst layers coated using two R2R coating methods: slot-die and gravure. These two methods were selected because the physics of applying the liquid to the substrate is very different between the two cases. Pt/C catalysts layers were coated directly onto carbon-fiber gas diffusion media to create gas diffusion electrodes (GDEs), without the use of a decal transfer process. These GDEs were assembled into membrane electrode assemblies (MEAs) by hot pressing to Nafion membranes. In situ performance and other electrochemical diagnostics were used to determine the influence of coating method on catalyst layer electrochemical properties. Electron microscopy was utilized to understand the influence of coating method on electrode morphology and its influence on electrochemical properties. We also explored the influence of solvent ratio to understand the potential coupling between ink formulation and coating methodology.

DIRECT ENERGY CONVERSION,MATERIALS SCIENCE↗
DOE OSTI2023

Tracking Flows of End-of-Life Battery Materials and Manufacturing Scrap

This paper defines terms such as “recycling rate” that enable the characterization of flows of battery materials and expands the terminology to accommodate the description of complex product recycling. It also estimates the maximum percentage of U.S. demand for critical elements that could be satisfied by recycling as demand continues to grow, and it defines and estimates the recycling rate for lithium-ion batteries. Finally, it clarifies the role of manufacturing scrap as the domestic U.S. supply chain is built up. It concludes that recycling will be important in the long term, but growth still requires that new material be extracted to supply additional material.

25 ENERGY STORAGE↗
DOE OSTI2023

Evidence of hexagonal germanium grains on annealed monolayer MoS 2

Growing three-dimensional (3D) materials on two-dimensional (2D) van der Waals surface has shown its effectiveness in overcoming materials incompatibility for stacking transferrable membranes toward advanced device manufacturing. Herein, we demonstrate that the nucleation of hexagonal germanium (Ge) grains within a continuous crystalline film, which has been unfeasible through traditional epitaxy techniques, is realized by chemical vapor deposition on top of n-type monolayer molybdenum disulfide (MoS 2 ) substrates. Suggested by quantum molecular dynamics calculation, the hexagonal Ge nucleation is thermodynamically preferable to cubic Ge when growing on monolayer MoS 2 with sulfur vacancies. The strained hexagonal Ge grains have been confirmed by transmission electron microscopy analyses from both real space and reciprocal space. Scanning probe microscopy shows that the hexagonal Ge film possesses higher reflectivity in infrared spectral range, implying a higher carrier concentration resulted from the narrower band gap, as compared to cubic Ge.

36 MATERIALS SCIENCE↗