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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Solidification Technologies for Radioactive and Chemical Liquid Waste Treatment - Final CRADA Report

This project, organized under DOE/NNSA's Global Initiatives for Proliferation Prevention program, joined Russian and DOE scientists in developing more effective solidification and storage technologies for liquid radioactive waste. Several patent applications were filed by the Russian scientists (Russia only) and in 2012, the technology developed was approved by Russia's Federal State Unitary Enterprise RADON for application throughout Russia in cleaning up and disposing of radioactive waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

High Temperature, High Pressure Equation of State: Solidification of Hydrocarbons and Measurement of Krytox Oil Using Rolling-Ball Viscometer Validation

The global consumption of oil and gas continues to rise and has led to the search and recovery of petroleum sources from reservoirs exhibiting increasingly high-temperature, high-pressure conditions. For example, ultra-deep petroleum formations found at depths of approximately 5 km or more, can exhibit pressure and temperature values as high as 240 MPa (35,000 psi) and 533 K (260°C). The hydrocarbons produced from these ultra-deep formations experience significant decreases in temperature and pressure from reservoir to platform conditions. Hence, it is highly desirable to develop accurate equation of state models (EOS) and fluid properties databases that covers the entire temperature and pressure ranges associated with this process to promote the efficient, safe, and environmentally responsible production from these reservoirs at extreme conditions. Currently available databases and EOS models are generally limited to approximately 69 MPa and do not correlate accurately when extrapolated to the extreme environments associated with ultra-deep reservoirs where temperatures can reach as high as 533 K and pressures up to 240 MPa. Despite recent exploration and production of petroleum from ultra-deep formations, there are major gaps in the databases for pure and mixture density and viscosity of hydrocarbons. These are the most important fluid properties that enable accurate booking of reserves as well as the design of size and equipment to safely bring these fluids to the platform. The overall objective of this project is to develop methodologies to provide crude oil thermodynamic and transport properties—including density, viscosity, and phase composition— at extreme temperature and pressure conditions. The knowledge of these crude oil properties reduces uncertainties associated with deep drilling and promotes safer and reliable access to domestic energy resources. This report is an extension of work reported in our first Technical Report Series (TRS) released July 31, 2012: High Temperature, High Pressure Equation of State Density Correlations and Viscosity Correlations (Tapriyal et al., 2012). New experimental data were obtained by utilizing density cell and rolling-ball viscometer (both designed by our team) rated up to 533 K and 275 MPa. This report focuses on the solidification of hydrocarbons at elevated temperatures and pressures and

02 PETROLEUM↗
DOE OSTI2018

Homogeneous vs. Heterogeneous Nucleation Modes of Solidification at Strong Driving Force Conditions

We summarize and numerically estimate, in a simple form, the major relationship and parameters of classical nucleation theory (CNT) toward the problem of solidification under extreme conditions of large driving force. The effect of reduced quantities such as the interfacial free energy and chemical potential difference is explored under both heterogeneous and homogeneous modes of nucleation. It is shown when under strong driving force conditions, total homogeneous nuclei production within the bulk may exceed the production by heterogeneous nucleation sources.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Laser Intensity Profile Effects on the Solidification Microstructure of Ti-6Al-4V and Ti-5553

Traditional machining of Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr (Ti-5553) is challenging due to high chemical reactivity, adiabatic shear band formation, and material cost. Titanium is attractive because of its high tensile strength, low density, corrosion resistance, and ability to withstand extreme temperatures. Selective Laser Melting (SLM) is capable of manufacturing geometrically complicated parts at a lower expense. Exceptional tolerances can be obtained with properly tuned processing parameters. Alterations on scan parameters permit microstructure and melt pool control. Single track laser melting experiments were performed on Ti-6Al-4V and Ti- 5553 using elliptical intensity profiles. Results show that maintaining constant energy density but increasing power results in a melt pool failing to penetrate the substrate for Ti-5553. Increasing laser energy density increases melt pool width and can increase powder bed denudation. Comparing Ti64 and Ti-5553 microstructures contributes to a better understanding of rapid solidification in titanium.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Intensified Flue Gas Desulfurization Water Treatment for Reuse, Solidification, and Discharge

The goal of this final project report is to summarize the work conducted on project DE-FE0031555. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Center for Applied Energy Research (UK CAER) (Recipient) developed a hybrid electrochemical-membrane technology for treating wet flue gas desulfurization (WFGD) blowdown from coal-fired power generation plants that (1) removes government-regulated species and total suspended solids (TSS) via electrocoagulation with solid/liquid separation to avoid further treatments by a biological method specifically for selenium, and (2) reduces total dissolved solids (TDS) in a nanofiltration unit to promote water recycle and reduce freshwater intake. Additional technological configurations were pursued, including (1) nanofiltration combined with zeolite dewatering for a near-zero liquid discharge (ZLD) scenario, and (2) polishing discharge from zeolite dewatering using capacitive deionization (CDI) with 90+% salt rejection to produce water with less than 100ppm TDS for more beneficial use. Project results verified that UK CAER’s hybrid approach addressed the complexities of WFGD blowdown with simplified unit operation at relatively low capital investment by demonstrating: (1) an effective in-situ generated solid sorbent material, green-rust (GR), that specifically removes regulated dissolved species in WFGD blowdown, including selenium, arsenic, and nitrates; (2) a low-cost, high flux nanofiltration treatment that removes both monovalent and divalent species at >80% rejection to adequately provide water recycle and extend the life of FGD equipment by mitigating chloride aided pitting corrosion mechanisms; and (3) a solidification and stabilization process using pozzolanic agents that retain regulated species and satisfy the Resource Conservation and Recovery Act (RCRA) leachate requirements. UK CAER proved electrocoagulation with GR to be an intensified solution for effluent limit guidelines (ELG), and based on preliminary techno-economic analysis (TEA), in comparison to DOE’s Case 1 for Biological Wastewater Treatment that had a purchased equipment cost (PEC) of $\$$5.26 million and a Total plant cost (TPC) of $\$$30.0 million, the EC process had a PEC of $\$$2.67 million and the TPC of $\$$17.0 million. While the electricity consumption for Case 1 was 53 kW, it was 110 kW for the EC process due to dissolving iron for a three-stage reaction design. However, electricity consumption for the EC process could be significantly reduced by adopting a counter-current reactor design for at least a 6-stage chemical reaction operation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Probing the solidification of quasicrystals via joint experiment and simulation (Final Report)

Quasicrystals (QCs) possess long-range positional order but non-crystallographic orientational order. Their classically ‘forbidden’ symmetry has long attracted the interest of scientists worldwide. Despite their frequent observation in both metal alloys and soft matter structures in the 35 years since their discovery, little is known about how QCs evolve from a liquid, amorphous, or crystalline precursor. In this project, we sought to resolve the enigma of QC self-assembly through a combined experimental and computational program. The Shahani group employed in situ electron and synchrotron X ray imaging to peer into the growth dynamics of QCs in a liquid, covering a broad range of length scales and solidification pathways. Glotzer's team developed new simulation models incorporating phasonic defects — which are unique to quasicrystals — and used this model to investigate two grains growing together, closely mimicking the experimental conditions. While QCs remain exceptional structures, most compounds in the realm of intermetallics adopt non-trivial geometries. In fact, only around 6% of phases are comprised of the simplest sphere packings that researchers so readily associate with metals. State-of-the-art knowledge of phase transformations at the outset of this collaborative project did not encompass the remaining 94% of intermetallic compounds that possess complex and aperiodic structure types. Therefore, we expect that outcomes from this project will have immediate and profound impact on synthesis and processing science: our efforts will be used to not only explain the growth dynamics of QCs but also complex intermetallics more broadly.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An Implicit Approach to Phase Field Modeling of Solidification for Additively Manufactured Alloys [Slides]

We are leveraging modern algorithms and computational science to provide a route to predictive simulation of microstructure evolution on emerging exascale architectures. We are utilizing the fastest supercomputers in the world for modeling and simulation of microstructure evolution for generation of data under AM conditions. Solidification conditions in AM can be tailored for the reliable design of materials to specific performance requirements. Developing computational tools to further characterize alloys and correlate the processing-structure-properties-performance (PSPP) relationship.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Volume Change from Solidification Correlation for Hanford Tank Waste.

The U.S. Department of Energy (DOE), Hanford Field Office’s primary mission is to safely and effectively treat Hanford’s tank waste and deliver environmental remediation. Mixed radioactive waste is stored in the underground tanks at the Hanford Site. It was recently estimated that retrieval of the waste in the 200 West Area underground tanks in the SY, S, SX, and U Tank Farms will result in about 41 million gallons of mixed low-level waste (MLLW) (RPP-RPT-65147, Rev. 1). The current plan is to retrieve at least 22 S, SX, and U Farm tanks and pretreat1 to produce pretreated tank waste (PTW) which will be further treated (including solidification /immobilization) for Resource Conservation and Recovery Act (RCRA) Land Disposal Restriction (LDR) organics and inorganics before being transferred to an offsite out-of-state facility for disposal (RPP-PLAN-66135, Rev. 2). In addition, solidified PTW from the 200 East Area may also be transferred to an offsite out-of-state facility for disposal to ensure availability of critical Double-Shell Tank space, meet retrieval obligations, and optimize 200 East Area operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Solidification and Re-melting Phenomena During Slurry Preparation Using the RheoMetal™ Process

The melting sequence of the enthalpy exchange material (EEM) and formation of a slurry in the RheoMetal™ process was investigated. The EEM was extracted and quenched, together with a portion of the slurry at different processing times before complete melting. The EEM initially increased in size/diameter due to melt freezing onto its surface, forming a freeze-on layer. The initial growth of this layer was followed by a period of a constant diameter of the EEM with subsequent melting and decrease of diameter. Microstructural characterization of the size and morphology of different phases in the EEM and in the freeze-on layer was made. Dendritic equiaxed grains and eutectic regions containing Si particles and Cu-bearing particles and Fe-rich particles were observed in the as-cast EEM. The freeze-on layer consisted of dendritic aluminum tilted by about 30 deg in the upstream direction, caused by the rotation of the EEM. Energy dispersion spectroscopy analysis showed that the freeze-on layer had a composition corresponding to an alloy with higher melting point than the EEM and thus shielding the EEM from the surrounding melt. Microstructural changes in the EEM showed that temperature rapidly increased to 768 K (495 °C), indicated by incipient melting of the lowest temperature melting eutectic in triple junction grain boundary regions with Al{sub 2}Cu and Al{sub 5}Mg{sub 8}Si{sub 6}Cu{sub 2} phases present. As the EEM temperature increased further the binary Al-Si eutectic started to melt to form a region of a fully developed coherent mushy state. Experimental results and a thermal model indicated that as the dendrites spheroidized near to the interface at the EEM/freeze-on layer reached a mushy state with 25 pct solid fraction, coherency was lost and disintegration of the freeze-on layer took place. Subsequently, in the absence of the shielding effect from the freeze-on Layer, the EEM continued to disintegrate with a coherency limit of a solid fraction estimated to be 50 pct.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Formation Mechanism of Stray Grain of Nickel-Based Single-Crystal Superalloy Under a High Magnetic Field During Directional Solidification

We investigate the formation mechanism of stray grain of nickel-based single-crystal superalloy under a high magnetic field. It was shown that the high magnetic field induced the formation of stray grains on the side that the dendrite diverges the wall. In addition, results showed a sloping solid/liquid interface and a further increased sloping magnitude under a high magnetic field. Further, the formation process of stray grain in the high magnetic field is analyzed in detail.

36 MATERIALS SCIENCE↗
DOE OSTI2022

ExaCA: A performance portable exascale cellular automata application for alloy solidification modeling

Modeling the as-solidified grain structures that form during alloy processing is a critical component in understanding process-property relationships, particularly for additive manufacturing (AM) where grain structure is very sensitive to processing conditions. While cellular automata (CA)-based models have proven able to predict aspects of microstructure for several alloys and AM process conditions, long run times and large resource sets required limit the utility and the problem size to which existing CA models can be applied. As part of the ExaAM project, an initiative within the Exascale Computing Project (ECP) to develop, test, and optimize an exascale-capable coupled and self-consistent model of AM parts, we developed ExaCA (https://github.com/LLNL/ExaCA) for the liquid–solid phase transformation in the wake of AM melt pools. The CA-based code is parallelized using MPI and the Kokkos programming model, the latter enabling simulation on both CPUs and GPUs within a single-source implementation. Here, we detail the steps taken to transform a baseline, MPI-based CA code into one that is performant on CPUs and GPUs. Performance testing of ExaCA on Summit (a pre-exascale machine at Oak Ridge National Laboratory) was used to quantify CPU–GPU speedup comparing with equal numbers of nodes. Testing showed comparable CPU performance to the MPI-only CA code and a 5-20x speedup when running AM-based test problems using GPUs. The improved performance of CA through GPU utilization and the performance portable nature of ExaCA will enable accurate part-scale modeling by harnessing the power of current and future generations of high performance computing resources. Future work will include improving the strong scaling of ExaCA on GPUs by reducing load imbalance associated with the locality of the problem, and continuing performance optimization across exascale hardware.

36 MATERIALS SCIENCE↗
DOE OSTI2014

X-ray nano-diffraction study of Sr intermetallic phase during solidification of Al-Si hypoeutectic alloy

The evolution of strontium (Sr) containing intermetallic phase in the eutectic reaction of Sr-modified Al-Si hypoeutectic alloy was studied with high energy synchrotron beam source for nano-diffraction experiments and x-ray fluorescence elemental mapping. Contrary to popular belief, Sr does not seem to interfere with the Twin Plane Re-entrant Edge (TPRE) growth mechanism of eutectic Si, but evolves as the Al{sub 2}Si{sub 2}Sr phase during the eutectic reaction at the boundary between the eutectic Si and Al grains.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗