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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Neutron Imaging of Al6061 Prepared by Solid-State Friction Stir Additive Manufacturing

Solid-state Friction Stir Additive Manufacturing has recently gained attention as a result of its capacity to fabricate large-scale parts while preserving the mechanical properties of the feedstock material. However, the correlation between the quality of layer-by-layer bonding of the deposited metal and processing parameters has remained unknown. Neutron imaging techniques, with 90% total transmission per cm, are employed for Al6061 parts fabricated by MELD ® Technology as a non-destructive evaluation approach for the first time to investigate the layer-by-layer structure of a stadium-shaped ingot in different sections. The post-processed results show the fabricated parts with an optimized set of processing parameters are void-free. However, the hydrocarbon-based feedstock lubricant segregates between the layers, which consequently may lead to non-uniform weaker mechanical properties along the build direction and stimulate crack initiation during mechanical loading. The tensile test results show 14% lower strain-to-failure values in alleged contaminated areas in transmission imaging results. Additionally, layer bonding is significantly impacted by hot-on-hot and hot-on-cold layer deposition schemes, especially for larger layer thicknesses.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗
DOE OSTI2021

Reconstructing Masses of Merging Neutron Stars from Stellar r -process Abundance Signatures

We report that neutron star mergers (NSMs) are promising astrophysical sites for the rapid neutron-capture ("r") process, but can their integrated yields explain the majority of heavy-element material in the Galaxy? One method to address this question implements a forward approach that propagates NSM rates and yields along with stellar formation rates and compares those results with observed chemical abundances of r-process-rich, metal-poor stars. In this work, we take the inverse approach by utilizing r-process-element abundance ratios of metal-poor stars as input to reconstruct the properties -especially the masses - of their neutron star (NS) binary progenitors. This novel analysis provides an independent avenue for studying the population of the original NS binary systems that merged and produced the r-process material now incorporated in Galactic metal-poor halo stars. We use ratios of elements typically associated with the limited-r-process and the actinide region to those in the lanthanide region (i.e., Zr/Dy and Th/Dy) to probe the NS masses of the progenitor merger. We find that NSMs can account for all r-process material in metal-poor stars that display r-process signatures, while simultaneously reproducing the present-day distribution of double-NS systems. Notably, with our model assumptions and the studied stellar sample, we postulate that the most r-process enhanced stars (the r–II stars) on their own would require progenitor NSMs of asymmetric systems that are distinctly different from present ones in the Galaxy. We also explore variations to the model and find that the predicted degree of asymmetry is most sensitive to the electron fraction of the remnant disk wind.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Collapsar R-process Yields Can Reproduce [Eu/Fe] Abundance Scatter in Metal-poor Stars

It is unclear if neutron star mergers can explain the observed r-process abundances of metal-poor stars. Collapsars, defined here as rotating massive stars whose collapse results in a rapidly accreting disk around a black hole that can launch jets, are a promising alternative. We find that we can produce a self-consistent model in which a population of collapsars with stochastic europium yields synthesizes all of the r-process material in metal-poor ([Fe/H] < - 2.5) stars. Our model reproduces the observed scatter and evolution of scatter of [Eu/Fe] abundances. We find that if collapsars are the dominant r-process site for metal-poor stars, r-process synthesis may be linked to supernovae that produce long γ-ray bursts. Our results also allow for the possibility that core-collapse supernovae beyond those that launch γ-ray bursts also produce r-process material (e.g., potentially a subset of Type Ic-BL supernovae). Furthermore, we identify collapsar jet properties (isotropic energy, engine luminosity, or engine time) that may trace r-process yield and verify that the amount of r-process yield produced per collapsar in our model ( ~ 0.07M⊙) is consistent with other independent estimates. In the future, achieving 0.05 dex precision on distribution scatter or a reliable selection function would further constrain our probe of r-process production. Our model would also hold for another prompt r-process site with a power-law yield, and work is needed to determine if, for example, fast-merging neutron stars can also explain abundance scatter.

Astronomy & Astrophysics↗
DOE OSTI2022

All-atmospheric fabrication of Ag–Cu core–shell nanowire transparent electrodes with Haacke figure of merit >600 × 10–3 Ω−1

Abstract Transparent conducting electrodes (TCEs) are essential components in devices such as touch screens, smart windows, and photovoltaics. Metal nanowire networks are promising next-generation TCEs, but best-performing examples rely on expensive metal catalysts (palladium or platinum), vacuum processing, or transfer processes that cannot be scaled. This work demonstrates a metal nanowire TCE fabrication process that focuses on high performance and simple fabrication. Here we combined direct and plating metallization processes on electrospun nanowires. We first directly metallize silver nanowires using reactive silver ink. The silver catalyzes subsequent copper plating to produce Ag–Cu core–shell nanowires and eliminates nanowire junction resistances. The process allows for tunable transmission and sheet resistance properties by adjusting electrospinning and plating time. We demonstrate state-of-the-art, low-haze TCEs using an all-atmospheric process with sheet resistances of 0.33 Ω sq −1 and visible light transmittances of 86% (including the substrate), leading to a Haacke figure of merit of 652 × 10 –3 Ω −1 . The core–shell nanowire electrode also demonstrates high chemical and bending durability.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Advanced Processing of Rare Earth Elements and Critical Minerals from Acid Mine Drainage Feedstocks

Ongoing work by the project team identified a process for extracting rare earths and critical mineral (REE/CM) concentrates from acid mine drainage from coal mines, a major stream pollutant. The process removes harmful metals and separates REE/CM into economically attractive concentrates. This project explored the processing of those concentrates into individually separated, high purity metals, suitable for domestic manufacturers. The team brought unique experience in working with AMD-based feedstocks since the inception of USDOE’s coal-based REE/CM program in 2016. The project team has pioneered the recovery of rare earth/critical minerals (REE/CM) from acid mine drainage (AMD). This environmentally beneficial strategy will incentivize AMD treatment while recovering materials critical to the Nation’s defense and advanced manufacturing industries. In addition, the project will investigate the co-production of five high purity CMs from AMD, namely Co, Mn, Li, Cr, Ge. This team’s upstream and midstream recovery and processing technology has been demonstrated at the continuous, small scale pilot scale. In conjunction with the West Virginia Department of Environmental Protection, the team is constructing a full-scale, integrated, 500 gpm AMD treatment plant coupled with an REE/CM facility that will produce 21 tons REE/CM per year. Commissioning is scheduled for September 2021. This will provide feedstock for the team’s proprietary downstream processes that met the project objective: production of individually separated, high purity (ISHP) REE/CM oxides and their further processing to elemental metals (REM). To facilitate entry into the U.S. market, we have teamed up with companies that would use our products to strengthen their domestic supply chains and grow REE/CM based manufacturing in the U.S. They include Rockwell Automation, Rivian, Endress+Hauser, Inc., Northrop Grumman and Hela Novel Metals.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing

Artificial intelligence (AI) embedded within digital models of manufacturing processes can be used to improve process productivity and product quality significantly. The application of such advanced capabilities particularly to highly digitalized processes such as metal additive manufacturing (AM) is likely to make those processes commercially more attractive. AI capabilities will reside within Digital Twins (DTs) which are living virtual replicas of the physical processes. DTs will be empowered to operate autonomously in a diagnostic control capacity to supervise processes and can be interrogated by the practitioner to inform the optimal processing route for any given product. The utility of the information gained from the DTs would depend on the quality of the digital models and, more importantly, their faster-solving surrogates which dwell within DTs for consultation during rapid decision-making. In this article, we point out the exceptional value of DTs in AM and focus on the need to create high-fidelity multiscale-multiphysics models for AM processes to feed the AI capabilities. We identify technical hurdles for their development, including those arising from the multiscale and multiphysics characteristics of the models, the difficulties in linking models of the subprocesses across scales and physics, and the scarcity of experimental data. We discuss the need for creating surrogate models using machine learning approaches for real-time problem-solving. We further identify non-technical barriers, such as the need for standardization and difficulties in collaborating across different types of institutions. We offer potential solutions for all these challenges, after reflecting on and researching discussions held at an international symposium on the subject in 2019. Here, we argue that a collaborative approach can not only help accelerate their development compared with disparate efforts, but also enhance the quality of the models by allowing modular development and linkages that account for interactions between the various sub-processes in AM. A high-level roadmap is suggested for starting such a collaboration.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Real-time visualization of particle evolution during reactive flux-assisted processing of aluminum melts

Here, a multi-modal, multi-scale correlative tomography investigation of Al-TiC metal matrix composites processed via flux-assisted reaction synthesis is reported. Synchrotron X-ray microradiography is utilized to visualize the reaction and particle evolution in real-time. Changes in particle diameter and areal number density suggest that the process is nucleation- rather than growth-dominated. At 950 °C, the bulk of the reaction takes place in a relatively short time span of less than 600 s. The microstructure is imaged at higher resolution in 2D (scanning electron microscopy) and 3D (synchrotron X-ray nanotomography), revealing the formation of carbide particles with a hexagonal platelet morphology. We propose that the morphology arises due to the incorporation of Si impurities during the experiment. It is expected that the correlative tomography workflow and analysis may guide future metal matrix composite (MMC) processing strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of Luminescent Materials and Instrumentation for Critical Mineral Discovery and Monitoring

Presentation discussing career paths in chemistry as well as how chemical research is applied to address real-world problems. Here, a variety of different materials (metal-organic frameworks, carbon dots, thin films, etc.) are used as luminescent sensors to detect trace quantities of economically critical metals, which are used in applications ranging from renewable energy to national defense. In an application particularly relevant to Western Pennsylvania, the sensor technologies are deployed in coal utilization byproducts including fly ash leachates and acid mine drainage. Taken together, this research presents an exciting path towards reducing the characterization costs associated with metals prospecting and process monitoring, facilitating domestic production of these metals.

analytical chemistry↗
DOE OSTI2025

Dehydration of Methyl Lactate on Alkali Cation-Exchanged Faujasite: Effects of Metal Cation Identity and Water Pressure

Turnover rates for the catalytic dehydration of methyl lactate (ML) over ion-exchanged faujasite (FAU) catalysts depend on the identity of alkali metal cations (Na + , K + , Cs + ) and local solvation effects. Analysis of rate measurements and in situ infrared spectroscopy gives evidence that the reaction involves kinetically relevant dissociation of adsorbed methyl lactate upon alkali metal cations. This process involves concerted methyl transfer to the surface and dissociation of the alkali metal from the framework, which occurs at cationic active sites that remain predominantly unoccupied under relevant conditions (0.5–10 kPa ML, 0.5–15 kPa H 2 O, 563–583 K). Despite the mechanistic similarities, apparent activation enthalpies (ΔH app ‡ ) decrease linearly (47 kJ mol –1 from Na + to Cs + ) with ionization energy and cationic radius, and apparent activation entropies (ΔS app ‡ ) decrease 74 J mol –1 K –1 . These trends reflect electrostatic interactions that stabilize the cations to the anionic sites on the zeolite: stronger association between these charges leads to increasingly endothermic processes to displace the alkali metal to form a cationic methoxy and an intrapore metal lactate intermediate. Water physisorption measurements suggest alkali metal ions bind superstoichiometric quantities of water within FAU pores, and in situ infrared spectra suggest the concerted adsorption of ML requires reorganization of this water. Consequently, these processes introduce entropic gains that partially offset entropy losses associated with ML adsorption. Hence, turnover rates differ only by a factor of 2 among Na-, K-, and Cs-FAU at 573 K (ΔΔG app ‡ = 5 kJ mol –1 ). These findings demonstrate the interplay of alkali metal ions with zeolite active sites and intrapore water clusters for ML dehydration, indicating that these interactions can be leveraged to deliver optimal performance under different reaction conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Water-enhanced bifunctional metal-acid catalyst for C=C bond hydrogenation

Water-assisted proton shuttling can promote hydrogenation of polar functional groups, and it is generally believed that such an effect can be hardly applied to hydrogenation of C═C bonds due to the latter's weak interaction with water. Here, we report density functional theory calculations and metadynamics simulations, through which we show a dynamic bifunctional metal–acid site that can be transformed, when interacting with water, into an active configuration for unexpected water-enhanced proton shuttling to C═C bonds. In particular, we investigated B(OH)3 anchored to a Ni catalyst for hydrogenation of cyclohexene in an organic solvent, which showed in experiments an increased rate by 100 times when adding a small amount of water. Metadynamics simulations suggest that a B(OH)3–H2O cluster can form on Ni(111), which promotes the proton transfer in the first hydrogenation step, while the second hydrogenation is still driven by metal-mediated direct H-transfer. The recovery process of B(OH)3–H2O also involves a proton shuttling step. We find that the boric species on the surface serves as an electron reservoir and carries the negative charge to balance the positive charge in the proton transfer steps. This work thus provides fundamental insights into this dynamic transformation process of the metal–acid interface, which can in principle be applied to many other bifunctional systems for hydrogenating non-polar unsaturated groups by engineering the interfacial charge separation.

Sun, Shoutian↗
DOE OSTI2022

A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame rates of 20 kHz with a 2 µm pixel resolution, and the coincident diagnostic sensor data are recorded at 470 kHz. Furthermore, this work shows that the current system enables the in situ detection of defects during the LPBF process and permits direct correlation of diagnostic signatures at the exact time of defect formation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Metal Independent Correlations for Site-specific Binding Energies of Relevant Catalytic Intermediates

Establishing energy correlations among different metals can accelerate the discovery of efficient and cost-effective catalysts for complex reactions. Using a recently introduced coordination-based model, we can predict site specific metal binding energies (∆EM) that can be used as a descriptor for chemical reactions. In this study, we have examined a range of metals including Ag, Au, Co, Cu, Ir, Ni, Os, Pd, Pt, Rh, and Ru and found linear correlations between predicted ∆EM and adsorption energies of CH and O (∆ECH and ∆EO) at various coordination environment for all the considered metals. Interestingly, all the metals correlate with one another under specific surface site coordination, indicating that different metals are interrelated in a particular coordination environment. Furthermore, we have tested and verified for PtPd and PtIr-based alloys that they follow a similar behavior. Moreover, we have expanded the metal space by taking some early transition metals along with few s-block metals and shown a cyclic behavior of the adsorbate binding energy (∆EA) versus ∆EM. Therefore, ∆ECH and ∆EO can be efficiently interpolated between metals, alloys and intermetallics based on information related to one metal only. This simplifies the process of screening new metal catalyst formulations and their reaction energies.

Density function theory↗
DOE OSTI2020

Moderate-resolution K-band Spectroscopy of Substellar Companion κ Andromedae b

We present moderate-resolution (R ∼ 4000) K-band spectra of the “super-Jupiter,” κ Andromedae b. The data were taken with the OSIRIS integral field spectrograph at Keck Observatory. The spectra reveal resolved molecular lines from H{sub 2}O and CO, and are compared to a custom PHOENIX atmosphere model grid appropriate for young planetary-mass objects. We fit the data using a Markov chain Monte Carlo forward-modeling method. Using a combination of our moderate-resolution spectrum and low-resolution, broadband data from the literature, we derive an effective temperature of T {sub eff} = 1950–2150 K, a surface gravity of logg=3.5--4.5, and a metallicity of [M/H] = −0.2–0.0. These values are consistent with previous estimates from atmospheric modeling and the currently favored young age of the system (<50 Myr). We derive a C/O ratio of 0.70{sub −0.24}{sup +0.09} for the source, broadly consistent with the solar C/O ratio. This, coupled with the slightly subsolar metallicity, implies a composition consistent with that of the host star, and is suggestive of formation by a rapid process. The subsolar metallicity of κ Andromedae b is also consistent with predictions of formation via gravitational instability. Further constraints on formation of the companion will require measurement of the C/O ratio of κ Andromedae A. We also measure the radial velocity of κ Andromedae b for the first time, with a value of −1.4 ± 0.9 km s{sup −1} relative to the host star. We find that the derived radial velocity is consistent with the estimated high eccentricity of κ Andromedae b.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Chemical Process Safety at TRISO-Based, Metal-Based, and Salt-Based Fuel Fabrication Facilities: Technical Assessment and Guidance Assessment

As part of efforts to prepare for potential and ongoing safety reviews for licensing of advanced non-light-water reactor fuel cycles, the U.S. Nuclear Regulatory Commission (NRC) tasked Pacific Northwest National Laboratory to prepare an assessment on the state of knowledge of potential chemical processes at fuel cycle facilities supporting the front end of these fuel cycles, and to assess the associated regulatory guidance. This report provides a technical assessment of chemical process safety considerations to support NRC licensing reviews of fabrication processes for tri-structural isotropic (TRISO) based, metallic-based, and salt-based fuels. The assessments involved collecting publicly available information on the fuel fabrication processes to (i) identify the operational process steps, characteristics and chemicals involved, (ii) identify the physical safety considerations and health safety considerations during licensing reviews of the various process steps, and (iii) collect information to support assessments of severity of accidents and potential mitigative measures to be implemented. The assessment provides a foundational basis on chemical process safety considerations for advanced fuel fabrication activities, although it is recognized that licensing reviews may necessitate design-specific considerations. The specific conditions under which chemical hazards emerge will require process-specific considerations, highlighting the importance of process-informed interpretation. The assessment also determined that exposure guidelines and limits to assess the consequences of acute exposures are limited for some chemicals, although alternative limits and supplementary information from databases or safety data sheets provide sufficient information to evaluate consequences of acute exposures. In addition, it was identified that metallic and salt fuel fabrication processes may involve beryllium, which is an exposure hazard. The regulatory framework for the licensing of advanced fuel cycle facilities, per 10 CFR Part 70 Domestic Licensing of Special Nuclear Material, is deemed robust and flexible to address the chemical safety considerations in this report. A review was conducted on various regulatory guidance and technical basis documents. This included reviewing NUREG-1520, Revision 2, Standard Review Plan for Fuel Cycle Facilities License Applications – Final Report and the process descriptions in Appendix A of NUREG/CR-6410, Nuclear Fuel Cycle Facility Accident Analysis Handbook, to address advanced fuel types. As new fuels will involve process-specific chemical uses, process-specific considerations are provided in this report. Additionally, it is noted that the U.S. Department of Energy protective action criteria database includes Temporary Emergency Exposure Limits (TEELs) for process-specific chemicals. This report provides technical information to support chemical safety assessments of new advanced fuel cycle facilities and identifies technical and safety information to support licensing reviews. No regulatory barriers were identified for the licensing of advanced fuel cycle facilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗