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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

Comparative Life Cycle Assessment of Injection Molded and Big Area Additive Manufactured NdFeB Bonded Permanent Magnets

Permanent magnets are expected to play a crucial role in the realization of the clean economy. In particular, the neodymium-iron-boron (Nd2Fe14B or NdFeB) magnets, which have the highest energy density among rare earth permanent magnets, are needed for building more efficient windmill generators, electric vehicle motors, etc. Currently, near-net shape magnets can be either made through sintering and compression molding with extensive post machining or directly through injection molding. However, injection molding has a loading volume fraction limitation of 0.65 for nylon binders. A novel method of manufacturing bonded permanent magnets with loading fraction greater than 0.65 has been demonstrated using Big Area Additive Manufacturing (BAAM) printers. As energy density is directly proportional to the square of the magnet loading fraction, magnets produced using BAAM printers require less volume and magnetic material compared to that of injection molded magnets on average. A comparative LCA shows that this difference in magnetic powder consumption nearly constitutes the difference in the environmental impact categories. Even after assuming recycled magnetic input, the BAAM magnets perform better environmentally than injection molded magnets, especially in the ozone depletion category. Since BAAM printers can accommodate even higher loading fractions, at scale, BAAM printers possibly can bring about a significant decrease in rare earth mineral consumption and environmental emissions. So furthermore, single screw extrusion enables BAAM printers to have high print speeds and allow them to be economically competitive against injection molding. Therefore, BAAM printed magnets show promise in transitioning towards the clean economy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Particle Handling in Particle-Based Pumped Thermal Energy Storage

A particle-based pumped thermal electricity storage system stores high-temperature heat (~1000 degrees C) in low-cost silica sand and generates power through an efficient power cycle. Central to this system is a counterflow direct-contact gas/particle fluidized-bed heat exchanger, which can significantly improve the heat exchange process due to the large heat transfer surface area of particles. To showcase a lab-scale 10- to 20-kWe heat exchange process with particles heating up to 300 degrees C, a comprehensive hydrodynamic analysis of the fluidization condition inside the heat exchanger was conducted. The heat exchanger was designed to target for heat exchange process of 10-20 kW and accommodate an air mass flow rate of 0.3-0.7 kg/s. The fluidization condition was set to maintain stable bubbling fluidization, thereby maximizing the particle-to-air heat transfer. An air distributor was designed to equally distribute air over the bed, which can avoid defluidized zones in the heat exchanger. Additionally, particle handling systems including L-valves, screw conveyors, and pneumatic conveyors were developed for the prototype heat exchanger, efficiently conveying high-temperature particles at 0.2-0.5 kg/s. This work lays the foundation for scaling up the system and integrating it into larger energy storage applications, demonstrating its potential for efficient, high-temperature thermal energy storage and power generation.

25 ENERGY STORAGE↗
DOE OSTI2024

Electronic descriptors for dislocation deformation behavior and intrinsic ductility in bcc high-entropy alloys

Controlling the balance between strength and damage tolerance in high-entropy alloys (HEAs) is central to their application as structural materials. Materials discovery efforts for HEAs are therefore impeded by an incomplete understanding of the chemical factors governing this balance. Through first-principles calculations, this study explores factors governing intrinsic ductility of a crucial subset of HEAs—those with a body-centered cubic (bcc) crystal structure. Analyses of three sets of bcc HEAs comprising nine different compositions reveal that alloy chemistry profoundly influences screw dislocation core structure, dislocation vibrational properties, and intrinsic ductility parameters derived from unstable stacking fault and surface energies. Key features in the electronic structure are identified that correlate with these properties: the fraction of occupied bonding states and bimodality of the d-orbital density of states. The findings enhance the fundamental understanding of the origins of intrinsic ductility and establish an electronic structure–based framework for computationally accelerated materials discovery and design.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The chain of chirality transfer in tellurium nanocrystals

Despite persistent and extensive observations of crystals with chiral shapes, the mechanisms underlying their formation are not well understood. Although past studies suggest that chiral shapes can form because of crystallization in the presence of chiral additives, or because of an intrinsic tendency that stems from the crystal structure, there are many cases in which these explanations are not suitable or have not been tested. Here, an investigation of model tellurium nanocrystals provides insights into the chain of chirality transfer between crystal structure and shape. We show that this transfer is mediated by screw dislocations, and shape chirality is not an outcome of the chiral crystal structure or ligands.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Pseudogap and Fermi arc induced by Fermi surface nesting in a centrosymmetric skyrmion magnet

Skyrmions in noncentrosymmetric materials are believed to occur due to the Dzyaloshinskii-Moriya interaction. By contrast, the skyrmion formation mechanism in centrosymmetric materials remains elusive. Here, in this work, we reveal the intrinsic electronic structure of the centrosymmetric GdRu 2 Si 2 by selectively measuring magnetic domains using angle-resolved photoemission spectroscopy (ARPES). We found robust Fermi surface (FS) nesting, consistent with the magnetic modulation q -vector detected by the previous resonant x-ray scattering measurements. The pseudogap opens at the nested FS portions, which vary for different magnetic domains. The anomalous pseudogap disconnects the FS to generate Fermi arcs with twofold symmetry. These results indicate that the Ruderman-Kittel-Kasuya-Yosida (RKKY) interaction plays a decisive role in generating the screw spin modulation responsible for the skyrmion formation in GdRu 2 Si 2 . Furthermore, we demonstrate the flexible nature of magnetism in GdRu 2 Si 2 by manipulating magnetic domains with magnetic field and temperature cyclings, providing potential future applications for data storage and processing devices.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Characterization of textile-grade carbon fiber polypropylene composites

In this work, we consider low-cost carbon fiber produced with a textile-grade precursor. The objective of the study is to investigate textile-grade carbon-fiber-reinforced-polypropylene composites (TCF-PP) from compounded pellets for mechanical and thermal characterization. Four sets of pellets with 1%, 5%, 10%, and 15% reinforcement were manufactured using textile-grade carbon fiber (TCF) and polypropylene (PP) by twin-screw compounding. The addition of TCFs through gravimetric feeder directly in the extruder resulted in lower fiber content; however, side feeder has shown good potential. The pellets were further processed in extrusion compression molding to manufacture plaques. An increase in fiber loading has a negligible effect on fiber attrition as fiber length distribution variation between 1% and 15% reinforced pellets was very small. The addition of TCFs in PP showed a significant improvement in mechanical properties. The tensile strength and modulus of the composite were 26% and 161%, respectively, improved by the addition of 10 wt% TCF. Similar results were observed in the flexure test. However, the impact properties were reduced by 25.54% by the addition of 15% TCF.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Exploiting universal nonlocal dispersion in optically active materials for spectro-polarimetric computational imaging

Recent years have seen significant advancements in exploring novel light-matter interactions such as hyperbolic dispersion within natural crystals. However, current studies have predominantly concentrated on local optical response of materials characterized by a dielectric tensor without spatial dispersion. Here, we investigate the nonlocal response in optically-active crystals with screw symmetries, revealing their lossless, super-dispersive properties compared to traditional optical response functions. We leverage this universal nonlocal dispersion, i.e. the dispersion of optical rotatory power, to explore a novel spectral de-multiplexing scheme compared to conventional gratings, prisms and metasurfaces. We design and demonstrate an ‘Nonlocal-Cam’ - a camera that exploits nonlocal dispersion through sampling of polarized spectral states and the application of computational spectral reconstruction algorithms. The Nonlocal-Cam captures information in both laboratory and outdoor field experiments which is unavailable to traditional intensity cameras - the spectral texture of polarization. Merging the fields of nonlocal electrodynamics and computational imaging, our work paves the way for exploiting nonlocal optics of optically active materials in a variety of applications, from biological microscopy to physics-driven machine vision and remote sensing.

Wang, Xueji [Purdue Univ., West Lafayette, IN (Uni↗
DOE OSTI2020

Design of a Biomass Scale Cubical Triaxial Tester

The bioenergy industry is dependent on predictable and reliable feedstock handling equipment. High profile failures in the industry demonstrate the need for better modeling tools for feedstock handling, specifically tools which can model the bulk flow of biomass feedstock materials in handling equipment such as hoppers or screw conveyors. Measurement of bulk material flow characteristics is a critical component to inform modeling tools. Following examples in the soils and pharmaceuticals industries, a Cubical Triaxial Tester (CTT) was selected as a critical component to study relationships between applied stress on a bulk sample and the resulting strain on the bulk material. In cooperation with The Pennsylvania State University, Forest Concepts designed a CTT specifically to measure bulk biomass flowability characteristics. Several mechanical design constraints were identified to ensure proper scaling and repeatability. Major design constraints included sample chamber size versus particle length, volumetric strain sensing accuracy, independent axial pressure control, and sample chamber handling. This report explains how major design constraints were determined.

09 BIOMASS FUELS↗
DOE OSTI2026

Thermal images collected during 3D printing with Cincinnati BAAM

This data set contains images produced to test the performance of anomaly and fault detection methods in the context of additive manufacturing. A total of 10 print jobs were executed using a Cincinnati BAAM (model 606) with a Cincinnati medium compression screw. The material used was compounded polylactic acid (PLA) with wood flour as a filler produced by Jabil (80% NatureWorks Ingeo 6060D amorphous PLA, % 100 mesh pine flour from American Wood Fiber). Print sheets were 1/4in polycarbonate.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Defect identification in simulated Bragg coherent diffraction imaging by automated AI

X-ray Bragg coherent diffraction imaging is a powerful technique for operando and in situ materials characterization and provides a unique means of quantifying the influence of one-dimensional (1D) and two-dimensional (2D) material defects on material response. However, obtaining full images from raw x-ray diffraction data is nontrivial and computationally intensive, precluding real-time experimental feedback. Here, we present a machine learning approach to identify the presence of crystalline line defects (edge and screw) in samples from the raw, 2D, coherent diffraction data without the need for image reconstruction through iterative phase retrieval. Further, we compare different approaches to designing neural networks for this application and demonstrate the potential of automated ML (autoML) approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Models of dislocation glide and strengthening mechanisms in bcc complex concentrated alloys

Abstract The mechanical response of complex concentrated alloys (CCAs) deviates from that of their pure and dilute counterparts due to the introduction of a combinatorially sized chemical concentration dimension. Compositional fluctuations constantly alter the energy landscape over which dislocations move, leading to line roughness and the appearance of defects such as kinks and jogs under stress and temperature conditions where they would ordinarily not exist in pure metals and dilute alloys. The presence of such chemical defects gives rise to atomic-level mechanisms that fundamentally change how CCAs deform plastically at meso- and macroscales. In this article, we provide a review of recent advances in modeling dislocation glide processes in CCAs, including atomistic simulations of dislocation glide using molecular dynamics, kinetic Monte Carlo simulations of edge and screw dislocation motion in refractory CCAs, and phase-field models of dislocation evolution over complex energy landscapes. We also discuss pathways to develop comprehensive simulation methodologies that connect an atomic-level description of the compositional complexity of CCAs with their mesoscopic dislocation-mediated plastic response with an eye toward improved design of CCA with superior mechanical response. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2021

Elastic interaction-induced anisotropic growth of dislocation loop arrays

The elastic interactions and reactions of dislocations lead to the formation of complex dislocation substructures, which is critical to the strain hardening and fatigue failure. Phase field dislocation dynamics simulations are conducted as a first step to understand the elastic interactions between dislocation loops. When the interloop spacing is small, the elastic interactions with neighboring loops become strong, rendering the edge segments strongly pinned, while allowing for the screw segments to propagate more easily. The interactions are found to result in an anisotropic stress distribution around the dislocation loops, leading to the formation of arrays of long, straight edge dislocations that could act as barriers to subsequent slip. Furthermore, the effect of initial loop size and applied strain rate on the elastic interaction-induced anisotropic pinning effect is investigated and discussed. Furthermore, the results are important for coarse-graining dislocation substructures formation into continuum level models of deformation in crystalline solids.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Image quality indicator and dechromator setup for static LANSCE proton radiography experiment

This document describes a static geometry consisting of a sphere of gold and Ti-6Al-4V alloy, along with an energy-loss matching dechromator composed of polycarbonate, to field with the X3 electromagnetic magnifying lens at LANSCE during the next beam cycle. This static configuration will allow us to: (1) characterize the system’s resolution at the material interface between the gold and titanium alloy, and test the image quality for fine features associated with the screws used to fasten the titanium alloy hemispheres; (2) tune our models of proton scattering and imaging for these materials; and (3) test a procedure to align the polycarbonate dechromator and the sphere within the proton beamline. The data will also be suitable for validation of the software options available for proton radiography simulations.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Evaluation of the Volatile Species Associated with the K-Area Complex Blend Cans (D5043)

In the K-Area Complex (KAC), blend cans are used to down blend plutonium oxide for future disposal at the Waste Isolation Pilot Plant (WIPP). The blend can is a thin walled screw lid container that is used to down blend a measured amount of plutonium oxide with adulterant to reduce the attractiveness of the plutonium. The oxide and adulterant are mixed within the blend can and the blend can is packaged into a thick walled outer container. The blend cans are procured from an offsite vendor that uses a lubricant in the can manufacturing process. A thin coating of the lubricant adheres to the outer surface of the blend can and both inner and outer surfaces of the blend can cap.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Radiological Handling and Containment Considerations in Support of an American Medical Isotope Producer

This work will discuss evaluation and design of new and modified facility level radiological containment, transfer, and handling systems in support of the United States’ American Medical Isotope Production Act. In the United States alone, Molybdenum-99 (Mo-99) is used as a precursor to locally generate its decay product, technetium-99m (Tc-99m), for use in approximately 40,000 medical procedures every day to detect cancer and heart disease. Currently, however, Mo-99 is primarily produced overseas and typically requires highly enriched uranium (HEU) which is classified as weapon -usable. This poses a serious security risk to the United States and, in 2012, Congress passed the American Medical Isotope ACT which aimed to cease all Mo-99 production that requires HEU and support American based companies who have found safer production methods. Through this effort, a system was designed and developed to access irradiated material in processing hot cells for ease of material introduction and removal in the confined area. The proposed solution uses a double-door design that allows for easy access to material while also providing shielding through a mechanically manipulated carousel. A system was also designed to transport irradiated materials from target reactors to a target receipt box using a rail guide system, pneumatic motor, and lead screw drive.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Optical Imaging on Z LDRD: Design and Development of Self-Emission and Debris Imagers

We present an overview of the design and development of optical self-emission and debris imaging diagnostics for the Z Machine at Sandia National Laboratories. These diagnostics were designed and implemented to address several gaps in our understanding of visibly emitting phenomenon on Z and the post-shot debris environment. Optical emission arises from plasmas that form on the transmission line that delivers energy to Z loads and on the Z targets themselves; however, the dynamics of these plasmas are difficult to assess without imaging data. Addressing this, we developed a new optical imager called SEGOI (Self-Emission Gated Optical Imager) that leverages the eight gated optical imagers and two streak cameras of the Z Line VISAR system. SEGOI is a low cost, side-on imager with a 1 cm field of view and 30-50 µm spatial resolution, sensitive to green light (540-600 nm). This report outlines the design considerations and development of this diagnostic and presents an overview of the first diagnostic data acquired from four experimental campaigns. SEGOI was fielded on power flow experiments to image plasmas forming on and between transmission lines, on an inertial confinement fusion experiment called the Dynamic Screw Pinch to image low density plasmas forming on return current posts, on an experiment designed to measure the magneto Rayleigh-Taylor instability to image the instability bubble trajectory and self-emission structures, and finally on a Magnetized Liner Inertial Fusion (MagLIF) experiment to image the emission from the target. The second diagnostic developed, called DINGOZ (Debris ImagiNG on Z), was designed to improve our understanding of the post-shot debris environment. DINGOZ is an airtight enclosure that houses electronics and batteries to operate a high-speed (10-400 kfps) camera in the Z Machine center section. We report on the design considerations of this new diagnostic and present the first high-speed imaging data of the post-shot debris environment on Z.

42 ENGINEERING↗
DOE OSTI2021

Closing the Loop on Automotive Carbon Fiber Prepreg Manufacturing Scrap

The project demonstrated how to “close the loop” on carbon fiber by integrating industrial carbon fiber scrap into new functional components in an automotive lightweighting application. The project serves as a validation of discontinuous recycled carbon fiber in a commercial context, while generating comprehensive material data throughout the production chain. To this end, the project exhibited increasing complexity as material evaluation progressed from benchtop to commercial scale through full-scale part production, with key material properties thoroughly characterized throughout the process. Of particular focus was the form of the fiber that was fed into compounding, as recycled fiber has historically been problematic to feed at commercial-scale. Carbon fiber is energy-intensive to manufacture, so reuse of existing fiber material can reduce costs and increase sustainability. Additionally, by integrating recovered short fiber into a thermoplastic, regrind processes can be used to provide feedstock for later generations of product. While regrind plastics are not “infinitely recyclable”, reusing the manufacturing scrap over several generations of products can greatly increase material sustainability and lower the fractional embodied energy of each successive product. As such, this project supports the IACMI technical goals of (1) 25% lower carbon fiber-reinforced polymer (CFRP) cost, (2) 50% reduction in CFRP embodied energy, and (3) 80% composite recyclability into useful products. The initial stage of the project involved down selecting surface treatment (sizing) chemistries. Sizing evaluations were performed on Vartega’s chemically recycled intermediate modulus fiber along with standard modulus dry scrap which was oversized with sizing provided by Michelman. More dramatic improvements from sizing were found on the standard rather than the intermediate modulus fibers. The strength of the chemically recycled individual fibers were evaluated by Michelman and ORNL through single fiber testing and found to be comparable to similarly evaluated virgin fibers. UDRI’s mechanical testing on injection molded test specimens identified similar mechanical properties and fiber distribution relative to benchmark specimens. Additional surface chemistry tests and visualizations were performed by the Colorado School of Mines to confirm close conformance between the benchmark and recycled-fiber specimens. As the mechanical test results exceeded the 80% threshold established as the go/no-go(GNG), the project scale was increased to use commercial-scale equipment that would both better characterize the manufacturing utility of the target product format and allow qualitative assessment of a complex commercial part. An upscaled compounding evaluation was performed with a 27 mm twin-screw compounding extruding using oversized standard modulus fibers that were formatted to improve bulk solids transfer. The project team anticipated that milestone mechanical benchmarks could be achieved given the favorable performance of the sized standard modulus material identified in the initial micro-compounding trials. While the mechanical performance did meet the milestone target for that phase of the project, mechanical properties for this standard modulus-based compound were still less than those of the Ford specification. To compare the performance, the project team oversized intermediate modulus dry fibers and compounded them with the project resin at BASF using a 40 mm compounder. Test specimen mechanical performance exceeded the targets laid out in both the project milestone and the Ford specification. A series of prototype parts were successfully molded, albeit with instances of short shot components due to the high thermal conductivity of the carbon fiber compared to glass fiber for which the prototype tool was designed for. The project demonstrated that recycled carbon fiber is a viable option in fiber reinforced compound, providing greatly increased strength and modulus for applications that require them. The “agglomerated” format that facilitated effective bulk solids transfer of recovered fiber showed promise for industrial application.

36 MATERIALS SCIENCE↗