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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 OSTI2021

Multi-Process Tooling

Decisions made early in the automotive design process influence material selection, which in turn dictates process selection and tool design. Because of tool build time and cost of tooling, the original path is not easily altered, even if there is compelling evidence that another material or process would be beneficial. This project focused on tool design that is agile enough to allow its use in multiple processes—injection, injection compression, and extrusion-compression. This tool design allows for the manufacture of components with the most efficient process or materials, without building multiple, single-process tools. The primary purpose of the Multi-Process Tool project was to physically demonstrate that a single, well-designed tool could be used to manufacture parts with a variety of materials that require different processes. A multi-process tool would be beneficial to providing data for any changes to the process since materials and processes can be interchanged without incurring additional tool cost(s). Battery tray parts, (representative of a multi-process tool, were successfully manufactured using various types of materials, such as fiber reinforced (carbon fiber and/or glass fibers, recycled carbon fibers), amorphous (PP, TPU), semi-crystalline (PA6, PA66), and crystalline (thermoset epoxy resin) polymers. Processing of the parts was achieved by injection molding, compression molding, compression overmolding, and injection overmolding. Specimens extracted from various locations on the battery tray parts were evaluated for mechanical properties (flexure and interlaminar shear strength properties). The results show that the tool can be used to produce parts from a wide range of materials and processes with no degradation of the physical or cosmetic properties.

42 ENGINEERING↗
NASA NTRS1993

Hypersonic propulsion - Breaking the thermal barrier

The challenges of hypersonic propulsion impose unique features on the hypersonic vehicle - from large volume requirements to contain cryogenic fuel to airframe-integrated propulsion required to process sufficient quantities of air. Additional challenges exist in the design of the propulsion module that must be capable of efficiently processing air at very high enthalpies, adding and mixing fuel at supersonic speeds and expanding the exhaust products to generate thrust greater than drag. The paper explores the unique challenges of the integrated hypersonic propulsion system, addresses propulsion cycle selection to cope with the severe thermal environment and reviews the direction of propulsion research at hypervelocity speeds.

Weidner, J. P.↗
NASA NTRS1994

Agile manufacturing: The factory of the future

The factory of the future will require an operating methodology which effectively utilizes all of the elements of product design, manufacturing and delivery. The process must respond rapidly to changes in product demand, product mix, design changes or changes in the raw materials. To achieve agility in a manufacturing operation, the design and development of the manufacturing processes must focus on customer satisfaction. Achieving greatest results requires that the manufacturing process be considered from product concept through sales. This provides the best opportunity to build a quality product for the customer at a reasonable rate. The primary elements of a manufacturing system include people, equipment, materials, methods and the environment. The most significant and most agile element in any process is the human resource. Only with a highly trained, knowledgeable work force can the proper methods be applied to efficiently process materials with machinery which is predictable, reliable and flexible. This paper discusses the affect of each element on the development of agile manufacturing systems.

Loibl, Joseph M.↗
DOE OSTI2017

Application of HFE to the design and V and V of a computerized procedure system: benefits and challenges - 234

The application of Human Factors Engineering (HFE) practices to the Human Machine Interface design and subsequent Verification and Validation (V and V) is a widely applied practice when talking about the design of complete control rooms or important control room modernizations, but not so often applied to the design of computerized operator support systems. In order to overcome the challenges faced on designing a Computerized Operation Support System (COSS) that meets the process efficiency requirements and integrates seemingly with hybrid plant operation concept, the involvement of a HFE team early in the COSS design and implementation process along with operation, Instrumentation and Control (I and C) and cybersecurity experts will guarantee the project success. This paper documents the HFE process applied during the design and evaluation of a Computerized Procedure System (CPS) and how final product was shaped to ensure that the transition from paper to computerized procedures will help in meeting Delivering the Nuclear Promise (DNP) goals, improving plant efficiency. The HFE program included the following activities: 1. A review of existing operating experience 2. An analysis of functions and tasks associated to the use and maintenance of CPS 3. A design verification of the system to meet guidelines prescribed in the NUREG-0700 (Rev.2), requirements of the ISG-05 and cybersecurity criteria (NEI 08-09, IEC-62646, EPRI 1015313, these among others). 4. An integrated system validation in a full scope simulator The application of HFE practices in the design and implementation of COSS helps not only to ensure that efficiency and safety improvement requirements are met, but also to evaluate the potential return of the investment, that such tools should bring. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Process design for recovering rare-earth elements from mine tailings with low rare-earth concentrations via sequential leaching and solvent extraction

Rare earth elements (REEs) are essential for advanced technologies and yet face significant supply chain risks due to their concentrated global production and limited domestic availability. Addressing this challenge requires efficient processes capable of upgrading low-grade secondary resources such as mine tailings. In this study, we developed a novel separation flowsheet that integrates sequential leaching and 2-stage solvent extraction (SX) processes to recover high-purity heavy REEs (HREEs) and light REEs (LREEs) from a simulated mine-tailing concentrate containing 2.4 wt% total REEs (TREEs; 0.6 wt% LREEs and 1.8 wt% HREEs). Sequential leaching with controlled pH adjustment selectively precipitated REEs while retaining the large amount of impurities in the solution, producing an REE-enriched leachate by following leaching processes with roughly twice the REE concentration and half the impurity concentration compared to that of single-step leaching. The optimized SX flowsheet employed Cyanex 572 to extract HREEs and Fe over LREEs, followed by Fe removal using tributyl phosphate (TBP), while the raffinate stream was processed by SX with di(2-ethylhexyl)phosphoric acid (D2EHPA) to recover LREEs under optimized conditions balancing both extraction efficiency and purity. Although increased extractant availability in the organic phase improved LREE recovery, it also increased co-extraction of Ca, underscoring trade-offs in process optimization. Both HREE- and LREE-rich solutions were subsequently precipitated into solid products via oxalate precipitation, resulting in high-purity REE solids containing ∼92.0 wt% HREEs (∼95.7 wt% TREEs) and ∼92.8 wt% LREEs (∼94.0 wt% TREEs). In conclusion, this proof-of-concept study using simulated mine tailings demonstrates a promising approach for upgrading low-grade REE resources, while highlighting the need for future validation with real materials.

Mine tailings↗
DOE OSTI2014

The latest developments and outlook for hydrogen liquefaction technology

Liquefied hydrogen is presently mainly used for space applications and the semiconductor industry. While clean energy applications, for e.g. the automotive sector, currently contribute to this demand with a small share only, their demand may see a significant boost in the next years with the need for large scale liquefaction plants exceeding the current plant sizes by far. Hydrogen liquefaction for small scale plants with a maximum capacity of 3 tons per day (tpd) is accomplished with a Brayton refrigeration cycle using helium as refrigerant. This technology is characterized by low investment costs but lower process efficiency and hence higher operating costs. For larger plants, a hydrogen Claude cycle is used, characterized by higher investment but lower operating costs. However, liquefaction plants meeting the potentially high demand in the clean energy sector will need further optimization with regard to energy efficiency and hence operating costs. The present paper gives an overview of the currently applied technologies, including their thermodynamic and technical background. Areas of improvement are identified to derive process concepts for future large scale hydrogen liquefaction plants meeting the needs of clean energy applications with optimized energy efficiency and hence minimized operating costs. Compared to studies in this field, this paper focuses on application of new technology and innovative concepts which are either readily available or will require short qualification procedures. They will hence allow implementation in plants in the close future.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Quantum materials for energy-efficient neuromorphic computing: Opportunities and challenges

Neuromorphic computing approaches become increasingly important as we address future needs for efficiently processing massive amounts of data. The unique attributes of quantum materials can help address these needs by enabling new energy-efficient device concepts that implement neuromorphic ideas at the hardware level. In particular, strong correlations give rise to highly non-linear responses, such as conductive phase transitions that can be harnessed for short- and long-term plasticity. Similarly, magnetization dynamics are strongly non-linear and can be utilized for data classification. This Perspective discusses select examples of these approaches and provides an outlook on the current opportunities and challenges for assembling quantum-material-based devices for neuromorphic functionalities into larger emergent complex network systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An intelligent Data Delivery Service for and beyond the ATLAS experiment

The intelligent Data Delivery Service (iDDS) has been developed to cope with the huge increase of computing and storage resource usage in the coming LHC data taking. It has been designed to intelligently orchestrate workflows and data management systems, decoupling data pre-processing, delivery, and primary processing in large scale workflows. It is an experiment-agnostic service that has been deployed to serve data carousel (orchestrating efficient processing of tape-resident data), machine learning hyperparameter optimization, active learning, and other complex multi-stage workflows defined via DAG (Directed Acyclic Graph), CWL (Common Workflow Language) and other descriptions, including a growing number of analysis workflows. We will at first introduce some deployed use cases in a summary. Then we will focus on new improvements and use cases under developments in ATLAS, Rubin Observatory and sPHENIX, together with future efforts.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Variable Orientation of Biomass/Fast Microwave Pyrolysis Yield

Biomass that is considered “unusable” can be reused through the pyrolysis or extreme heating of mass with no oxygen. Pyrolysis can be an extremely beneficial practice for the fuel industry; however, the physical process of pyrolysis can be difficult to obtain consistent results. The goal to my research is to find a more physically efficient process to obtain an equal or greater amount of biofuel in comparison to the original process that is currently used. This will be obtained by pyrolyzing biomass pellets in different volumes and orientations and observation the results/yields.

09 BIOMASS FUELS↗
DOE OSTI2025

Fuel Salt Synthesis for the Molten Chloride Reactor Experiment: Scale-up, Operations, and Production Update

Over the previous 5 years, Idaho National Laboratory (INL) has been working with Southern Co. and TerraPower on the Advanced Reactor Demonstration Program (ARDP) funded Molten Chloride Reactor Experiment (MCRE) project. As part of this effort, INL has developed a fuel synthesis process to produce the NaCl-UCl3 fuel salt that MCRE will need for operation. Dr. Phillips will present on process development and scale-up testing and results, as well as provide an update on the current status of fuel production for MCRE. To date, the fuel synthesis process has been demonstrated at full scale using depleted uranium, and the equipment necessary for production of the fuel for MCRE has been installed in the Fuel Manufacturing Facility (FMF) at the INL’s Materials and Fuels Complex (MFC). The NaCl-UCl3 produced to-date has been shown to be of 99.99% purity or greater, and be within tolerance for all relevant parameters. Overall process efficiency in terms of uranium utilization has been demonstrated to be above 90%. The synthesis operation has also been shortened to allow for completion of the reaction within a single 10 hour working shift. Consequently, the process developed is expected to be capable of meeting all project objectives for efficiency, purity, scale, and scheduling. Production of NaCl-UCl3 fuel salt for MCRE is projected to begin during the Summer of 2025.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Solventless, Ambient-Pressure Production of Bio-Based Lactones Over Earth-Abundant, Mixed Metal Oxide Catalysts for Circular Polyesters

Transitioning to a circular plastics economy will require use of renewable feedstocks, energy-efficient processes, and closed-loop recyclable polymers, such as polyesters. A key challenge lies in sustainably sourcing monomers used to make recyclable polyesters. This work presents a catalytic platform utilizing earth-abundant Cu(x)Ca(1-x)O mixed metal oxides for the oxidative dehydrocyclization of bio-based diols to lactones, which are advantaged for energy-efficient ring-opening polymerization. Operating below 200 degrees C, at ambient pressure, and without solvent, the process uses air as the sole oxidant, achieving high yields of lactones across a broad substrate scope of C4-8 diols in the liquid phase. The oxidative dehydrocyclization reaction is thermodynamically downhill due to water formation and energy-efficient compared to incumbent, non-redox pathways utilized in fossil carbon-based industrial processes for lactone production. Mechanistic studies reveal facile redox cycling of Cu2+-O(Ca2+)-Cu2+ interfacial sites unique to the developed catalyst. Techno-economic analysis and life cycle assessment estimate 40% lower energy demand and 15% lower GHG intensity per mass of butyrolactone produced compared to the fossil carbon-based route. Liquid-phase oxidative dehydrocyclization offers a promising approach for scalable lactone production from renewable, bio-based diols to enable circular polyesters.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Characterization of dissolved organic matter in landfill leachate during the combined treatment process of air stripping, Fenton, SBR and coagulation

Highlights: • DOM fractions spectra analysis during the whole treatment process. • Efficient method was achieved to remove organic matters in landfill leachate. • Molecular weight distribution and fractions were discussed. - Abstract: A combined treatment process of air stripping + Fenton + sequencing batch reactor (SBR)+ coagulation was performed to remove the pollutants in landfill leachate. Molecular weight (MW) distribution and fractions of dissolved organic matter (DOM) were discussed to study the characteristics. The experiment showed that the removal rate of chemical oxygen demand (COD), five day biological oxygen demand (BOD{sub 5}) and ammonia nitrogen (NH{sub 3}−N) by the combined process were 92.8%, 87.8% and 98.0%, respectively. Humic acid (HA) and fulvic acid (FA) were the main fractions in raw leachate with 81.8% of the total COD concentration, while hydrophilic organic matter (HyI) was the dominant fraction in the final effluent of the combined process with 63.5% of the total COD concentration. After the combined treatment process, the removal rate of DOM and fractions HA, FA, HyI were 91.9%, 97.1%, 95.8% and 71.7%, respectively. Organic matters of MW < 2 k and MW > 100 k were removed with 90.5% and 97.9% COD concentration after the treatment. The ultraviolet–visible spectra (UV–vis), Fourier transform infrared spectra (FTIR) and three-dimensional excitation-emission matrices spectra (EEMs) indicated that benzene materials and phenol compounds were preferentially removed in air stripping. High MW matters, aromatic rings, conjugated moieties and some functional groups were mainly removed by Fenton. While small MW fractions, carboxylic acids, alcohols and protein-like materials were preferentially biodegraded via SBR. Fulvic-like and humic-like materials were mainly destroyed via Fenton oxidation and coagulation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Development of ITM oxygen technology for integration in IGCC and other advanced power generation

Ion Transport Membrane (ITM) technology is based on the oxygen-ion-conducting properties of certain mixed-metal oxide ceramic materials that can separate oxygen from an oxygen-containing gas, such as air, under a suitable driving force. The “ITM Oxygen” air separation system that results from the use of such ceramic membranes produces a hot, pure oxygen stream and a hot, pressurized, oxygen-depleted stream from which significant amounts of energy can be extracted. Accordingly, the technology integrates well with other high-temperature processes, including power generation. Air Products and Chemicals, Inc., the Recipient, in conjunction with a dozen subcontractors, developed ITM Oxygen technology under this five-phase Cooperative Agreement from the laboratory bench scale to implementation in a pilot plant capable of producing power and 100 tons per day (TPD) of purified oxygen. A commercial-scale membrane module manufacturing facility (the “CerFab”), sized to support a conceptual 2000 TPD ITM Oxygen Development Facility (ODF), was also established and operated under this Agreement. In the course of this work, the team developed prototype ceramic production processes and a robust planar ceramic membrane architecture based on a novel ceramic compound capable of high oxygen fluxes. The concept and feasibility of the technology was thoroughly established through laboratory pilot-scale operations testing commercial-scale membrane modules run under industrial operating conditions with compelling lifetime and reliability performance that supported further scale-up. Auxiliary systems, including contaminant mitigation, process controls, heat exchange, turbo-machinery, combustion, and membrane pressure vessels were extensively investigated and developed. The Recipient and subcontractors developed efficient process cycles that co-produce oxygen and power based on compact, low-cost ITMs. Process economics assessments show significant benefits relative to state-of-the-art cryogenic air separation technology in energy-intensive applications such as IGCC with and without carbon capture.

Armstrong, Phillip A.↗
NASA NTRS1974

A quantitative model for the potential resulting from reconnection with an arbitrary interplanetary magnetic field

A quantitative three-dimensional model is proposed for the electric potential arising from magnetopause reconnection, in which several approximations are made concerning configuration of the magnetosheath flow, limitations on the magnitude of the reconnection speed, and the geometry of the problem. These approximations are such that the model yields an upper limit for the potential. The magnitude of the polar cap ionospheric electric field computed from this model is larger than that measured on balloons by an average factor of about 3, and the model reproduces the temporal variations of the experimental data. It is concluded that magnetopause reconnection is a highly efficient process that is probably the dominant mechanism driving polar cap convection and supplying energy to the magnetosphere. It seems that the most efficient way for the solar wind to pass the magnetospheric obstacle is by magnetopause reconnection.

Gonzalez, W. D.↗
NASA NTRS2014

Integrating Land Cover Modeling and Adaptive Management to Conserve Endangered Species and Reduce Catastrophic Fire Risk

Land cover modeling is used to inform land management, but most often via a two-step process where science informs how management alternatives can influence resources and then decision makers can use this to make decisions. A more efficient process is to directly integrate science and decision making, where science allows us to learn to better accomplish management objectives and is developed to address specific decisions. Co-development of management and science is especially productive when decisions are complicated by multiple objectives and impeded by uncertainty. Multiple objectives can be met by specification of tradeoffs, and relevant uncertainty can be addressed through targeted science (i.e., models and monitoring). We describe how to integrate habitat and fuels monitoring with decision making focused on dual objectives of managing for endangered species and minimizing catastrophic fire risk. Under certain conditions, both objectives might be achieved by a similar management policy, but habitat trajectories suggest tradeoffs. Knowledge about system responses to actions can be informed by applying competing management actions to different land units in the same system state and by ideas about fire behavior. Monitoring and management integration is important to optimize state-specific management decisions and increase knowledge about system responses. We believe this approach has broad utility for and cover modeling programs intended to inform decision making.

adaptive management↗
NASA NTRS2018

Cassini In-Flight Navigation Adaptations

In the nearly two decades of Cassini flight, adaptations to navigation processes were applied as characteristics unique to Cassini were identified and spacecraft configuration changes were implemented. Additionally, operational experience was leveraged into more efficient processes, better modeling, and more robust contingency strategies. Trajectory adjustments were implemented to allow further investigation of surprising science discoveries meriting more attention. Unique analyses were performed to determine how to best accomplish atypical science observations while maintaining acceptable risk levels. Descriptions of the most significant adaptations are organized according to the affected navigation subsystems: trajectory design, orbit determination, optical navigation, and maneuver design.

Wagner, Sean↗
DOE OSTI2019

Mass Transfer and Reaction Kinetic Enhanced Electrode for High‐Performance Aqueous Flow Batteries

Abstract A scalable and efficient process to modify electrodes with enhanced mass transfer and reaction kinetics is critical for redox flow batteries (RFBs). For the first time, this work introduces electrochemical exfoliation as a surface modification method of graphite felt (GF) to enhance the mass transfer and reaction kinetics in RFBs. Anion intercalation and subsequent gas evolutions at room temperature for one minute expand the graphite layers that increase the electrode surface area. Meanwhile, sufficient oxygen functional groups are introduced to the electrode, resulting in enhanced reaction kinetics and improved hydrophilicity. Further, spin‐polarized density functional theory is employed to reveal the role of oxygen functional groups in accelerating the vanadium redox reaction. Benefitting from sufficient oxygen groups, larger surface area, and superior wettability, the as‐prepared exfoliated GF (E‐GF) shows exceptional electrocatalytic activity with minimized overpotential, higher volumetric capacity, and improved energy efficiency. The redox flow battery assembled with the E‐GF electrode delivers voltage and energy efficiencies of 89.72% and 86.41% at the current density of 100 mA cm −2 , respectively. Remarkably, compared to the traditional GF treatment method, the elimination of the high temperature and long‐time treatment processes make this approach much more energy and time efficient, scalable, and affordable for large‐scale manufacturing.

Mukhopadhyay, Alolika↗
DOE OSTI2017

Visual Sensing and Image Processing for Error Detection in Laser Metal Wire Deposition

Laser metal deposition with wire (LMD-w) involves feeding metal wire through a nozzle and melting the wire with a high-power laser. With efficient process control, comprising sensing, processing and feedback correction of errors, the technology has a potential of changing the course of manufacturing. However, the limitation most often encountered in LMD is the difficulty in controlling the process. Monitoring and control of metal additive manufacturing processes has been mostly researched on powder-based systems, and has not yet been investigated to much extent on the side of metal wire feed arrangements. This work proposes a method for detecting cavities in a deposited layer in the LMD-w process via optical inspection and processing of images obtained from a high-resolution camera. The aim is to develop an effective sensing module which automatically detects discontinuities in each layer before proceeding to subsequent layers, to reduce part porosity and improve inter-layer bond integrity.

Adediran, Adeola↗