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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Microchannel Reactor for Ethanol to Butene: CRADA 503 [Abstract only]

A key challenge facing most bioprocessing operations is that multiple unit operations are required, thereby resulting in complex, energy-intensive, and expensive processes. Further, biomass transportation costs drive the need for smaller, distributed processing plants. To incorporate the smaller scales desirable for biomass, novel processes must be developed with reduced capital costs. With over 20 years of experience in the development and commercialization of microchannel reactor technology, Oregon State University will partner with Pacific Northwest National Laboratory to demonstrate a microchannel reactor with lower capital costs for an alcohol-to-jet (ATJ) process technology that is currently being commercialized by LanzaTech. Ethanol can be produced from biomass feedstocks such as LanzaTech’s proprietary biochemical process using carbon from a number of possible feedstocks; syngas generated from biomass resources (e.g., MSW, organic industrial waste, agriculture waste) or reformed biogas, or from other biomass feedstocks such as corn kernel fiber. Ethanol then undergoes catalytic dehydration to form ethylene followed by a two-step oligomerization, hydrogenation, and fractionation to control the hydrocarbon product slate to the jet-range. Successful process development aided by a market pull for low carbon aviation fuel has spurred scale-up and commercial demonstration. However, Sustainable Aviation Fuel is a very price sensitive market and improved economics through process intensification will make the current ATJ process even more attractive. Recent efforts at PNNL have culminated in the development of a new catalyst technology for the conversion of ethanol to n-butene-rich olefins. A greater than 90% conversion, total olefin selectivity of 80-90% (n-butene selectivity ~60%), and good stability over a 100 hour test duration has been demonstrated at the bench scale. Producing butene-rich olefins directly from ethanol with high yield is new and impactful because the higher olefins can be selectively oligomerized to distillate-range hydrocarbons, thus eliminating one process step from the current ATJ process. Further, coupling the severely endothermic ethanol dehydration with exothermic C-C bond formation results in more energy efficient processing. Additional intensification and energy savings will stem from incorporating this new ethanol to n-butene catalyst technology within the ATJ process implemented using a microchannel reactor platform. Due to recent advances in microchannel manufacturing methods and associated cost reductions we believe the time is right to adapt this technology toward new commercial bioconversion applications.

02 PETROLEUM↗
DOE OSTI2026

Scalable, low-cost ink-based processing of high-performance silver selenide thermoelectrics

The growing global energy demand and its accelerating contribution to climate change emphasize the urgent need for sustainable energy conversion/harvesting technologies. Thermoelectric (TE) devices offer a compelling route to directly convert waste heat into electricity and enable solid-state cooling without moving parts or harmful refrigerants. Achieving their full potential requires not only higher TE performance (zT) but also scalable, low-cost manufacturing processes. Here, we introduce a transformative ink-based processing approach for scalable manufacturing of high-performance silver selenide-based TE materials and devices. Using a simple, high-throughput ink-mixing and blade coating strategy, our Ag 2 Se-based materials under the optimized composition and processing conditions yield an ultrahigh room-temperature power factor of 2.8 mW m −1 K −2 , over 100% higher than baseline samples and a reproducible figure of merit zT of 1 at room temperature. A thermoelectric generator (TEG) achieves a very competitive power density of 112 mW cm −2 at a 90 °C temperature difference between the hot and cold sides of the device, which is among the highest reported for silver selenide-based TE devices to date. This facile, scalable ink-based processing establishes a practical pathway toward industrial-scale manufacturing and widespread adoption of thermoelectric devices, advancing sustainable energy technologies.

Bappy, Md. Omarsany [University of Notre Dame, IN ↗
DOE OSTI2020

Enabling Deformable and Stretchable Batteries

Abstract Deformable energy storage devices are needed to power next‐generation wearable electronics that interface intimately with human skin. Currently, deformable energy storage devices demonstrate poor performance compared to their rigid lithium‐ion counterparts, forcing wearable manufacturers to design their devices around bulky battery compartments. However, technological advances to create deformable batteries at the component and device level have yielded continuous improvement in stretchable batteries over the last five years. In this Essay, the major strategies at the component and device level that have been successfully employed to create stretchable batteries are reviewed. The outstanding challenges facing deformable energy storage are also discussed, namely, energy density, packaging, delamination, device integration, and manufacturing. This Essay will give researchers who are interested in contributing to the development of deformable batteries a cursory understanding of the most successful strategies to date, and provide insights into the most important directions to pursue in the future.

Mackanic, David G.↗
DOE OSTI2024

Project DarkStar: Vision for LLNL in 2030

DarkStar was a Strategic Initiative (FY2021-FY2024) to investigate applications of Artificial Intelligence (AI) and Machine Learning (ML) to scientific problems of complex hydrodynamics, shockwave physics and energetic materials. The research focused on physics and engineering design as a process that can be tremendously accelerated through merging AI with advanced physics simulation on exascale-class platforms, and to experimentally validate this revolutionary new approach through dynamic materials campaigns. A central thread of scientific inquiry was in the application of AI to enable human understanding of how to control hydrodynamic instability (which has impacts to areas such as inertial confinement fusion) via engineering features and time-dependent sources. Motivated by an unfinished line of research started by Dr. Johnny von Neumann, AI-enabled simulation approaches were developed that allowed DarkStar researchers to uncover several ground-breaking discoveries regarding hydrodynamic instability, including how to completely suppress Richtmyer-Meshkov instability (RMI). These S&T discoveries, along with other advances, have shown the way for an entirely new approach to time-dependent problems known as inverse design – the idea that complex systems can be developed directly from a final state that is to be achieved and resolve the initial design via satisfying several constraints simultaneously via AI/ML. Through experimental campaigns conducted across a wide range of facilities in the NNSA complex (the High Explosive Application Facility at LLNL, the Dynamic Compression Sector/Advanced Photon Source at Argonne National Lab, and Special Technologies Laboratory at MSTS) the radical new AI/ML approach to engineering complex material dynamics was verified, establishing a new field of study within the realm of shock physics. As advanced manufacturing capabilities continue to develop, the great importance of inverse design as a means to apply that technology effectively for NNSA missions will feature prominently over this decade. DarkStar has positioned NNSA as a world-leader in this newly emerging cross-disciplinary area of AI methods for advanced physics simulation and pioneered multiple novel approaches that have enabled the broader scientific community. By allowing us to see past the horizon, to 2030 and beyond, DarkStar has illuminated the vast potential of AI/ML to impact a wide range of new national security missions and, consequently, multiple areas of further research have already emerged across the NNSA and DOD complex.

42 ENGINEERING↗
DOE OSTI2023

Cleaner Chips: Decarbonization in Semiconductor Manufacturing

The growth of the information and communication technology sector has vastly accelerated in recent decades because of advancements in digitalization and Artificial Intelligence (AI). Scope 1, 2, and 3 greenhouse gas emissions data of the top six semiconductor manufacturing companies (Samsung Electronics, Taiwan Semiconductor Manufacturing Corporation, Micron, SK Hynix, Kioxia, and Intel) were gathered from the publicly accessible Carbon Disclosure Project’s (CDP) website for 2020. Scope 3 emissions had the largest share in total annual emissions with an average share of 52%, followed by Scope 2 (32%) and Scope 1 (16%). Because of the absence of a standardized methodology for Scope 3 emissions estimation, each company used different methodologies that resulted in differences in emissions values. An analysis of the CDP reporting data did not reveal information on strategies implemented by companies to reduce Scope 3 emissions. The use of renewable energy certificates had the largest effect on decarbonization centered on reducing Scope 2 emissions, followed by the deployment of perfluorocarbon reduction technologies to help reduce Scope 1 fugitive emissions. Technology-specific marginal abatement costs of CO2 were also estimated and varied between −416 and 12,215 USD/t CO2 eq., which primarily varied depending on the technology deployed.

42 ENGINEERING↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS)

Opportunities exist for realizing transformative advances in productivity and reductions in energy footprint through ubiquitous sensing in manufacturing environments. Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS) is a 21-month (4 academic semesters, plus one summer) experience for graduate students that focuses on scaling the knowledge, understanding and leadership skills in the cyber manufacturing area. Masters students (8/year, 32 total) complete 2-year projects on industrially-driven project topics, rotating to internships in summer semester to work on scoping and implementation at project partners. Students complete academic training in embedded systems, process modeling, data science, and cloud-based systems design. Their projects are targeted toward sensor retrofit, process monitoring, root cause analysis, and sensor fusion.

Advanced Manufacturing↗
DOE OSTI2020

Innovative accident tolerant fuel concept enabled through direct manufacturing technology

Nuclear energy is one of the largest sources of carbon-free electricity in the world. Some countries are looking at new ways to support and revitalize the nuclear sector since the Fukushima disaster. The accident tolerant fuel program is geared toward improving the safety of nuclear energy by investigating materials that can replace or modify the current uranium-dioxide nuclear fuel and zirconium-based cladding. This research program is being supported by all major nuclear countries since 2011. The practical limitations on allowable uranium enrichment has taken the focus away from the most promising fuels with high radioactivity retention such as tristructural isotropic particle fuel. To overcome such enrichment limitation, a new fuel concept is proposed using advanced ceramic direct manufacturing with laser-induced chemical vapor deposition. The fuel-as-fiber concept is an accident-tolerant fuel design that features high thermal conductivity, strong capability of radioactivity retention and most importantly requires reasonable enrichment levels with uranium nitride as the fuel. In this work, the initial fabrication of uranium-based fuel with laser-induced chemical vapor deposition technology is demonstrated. Then an advanced multi-physics guided modeling approach based on finite element analysis codes and informed by the manufacturing capabilities is developed to accelerate the advancement of fuel-as-fiber concept for use in current light-water reactor technology. The detailed thermomechanical analysis showed promising results for viability of the innovative fuel-as-fiber concept. The predicted stresses in the fuel structural materials were similar to the case of tristructural isotropic particle fuel experience base that has shown excellent reliability in retention of fuel radioactivity at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Co-Extrusion (CoEx) for Cost Reduction of Advanced High-Energy-and-Power Battery Electrode Manufacturing

Co-Extrusion (CoEx) is a deposition technology developed at PARC that uses engineered fluidic channels to cause multiple streams of dissimilar fluids to impart shape to one another. Here, we describe the use of CoEx to produce structured cathode electrode films to improve electrochemical performance of thick electrode films. CoEx enables us to create structured electrode films that have periodic regions of enhanced ionic conductivity, enabling higher utilization of thicker cathode films at high discharge rates. While increasing electrode thickness is a known method for increasing energy density of battery electrodes, this increase in energy density typically also results in reduced power density. This project, a collaboration between the Palo Alto Research Center, Oak Ridge National Laboratories, and Ford Motor Company, seeks to first validate the benefits of CoEx at the coin cell level, before performing the necessary R&D effort to scale production up to large (10+ Ah) pouch cells that will show increased energy density without a reduction in power density. We used conventional battery materials (commercially available NMC, PVDF, carbon black, and graphite) to produce structured electrodes via CoEx and compared them to thick and thin conventionally produced (unstructured) battery electrodes. CoEx electrodes show improved high rate performance compared to unstructured electrodes, resulting in higher energy density pouch cells compared to the baseline electrode of 7 and 11% in volumetric and gravimetric energy density, respectively. These electrodes also showed substantially improved electrochemical performance at high discharge rates compared to thick conventional electrodes.

25 ENERGY STORAGE↗
DOE OSTI2021

Embedding Sensors in 3D Printed Metal Structures

The Transformational Challenge Reactor (TCR) program is leveraging recent advances in modeling and simulation, materials, and additive manufacturing (AM) technologies to design a modern nuclear reactor. Some of the main TCR technologies include in situ monitoring and the integration of sensors during the manufacturing of quality-significant nuclear reactor components. This report describes the general procedure and process optimization for embedding sensors within generic stainless steel 316 (SS316) components using laser powder bed fusion (LPBF). A more detailed, quality-significant test plan and supporting procedures are available upon request (ORNL/TM-2021/2127). LPBF involves the use of a scanning laser to selectively melt regions of a powder bed, additively building a part layer by layer. This report describes the LPBF processing technique and discusses the effects of LPBF processing parameters on the success of the sensor embedding process. Experiments used machined cavities in the form of channels in an SS316 base for the sensors to lay in while material is additively built over the top, thereby embedding them in an SS316 matrix. A preliminary investigation involved using empty SS316 sheaths as surrogates to explore the effects of various LPBF processing parameters and the dimensional requirements of the machined channels. Microstructural investigations showed that a smaller channel width/depth combination closer to the sensor’s diameter was best for the embedding process. After the desired parameters were selected, Type-K thermocouples were embedded and evaluated post-embedding using nondestructive thermal testing, as well as destructive sectioning and microscopy. Post-build characterization showed that the thermocouples were well-bonded to the SS316 matrix and were fully functional after embedding. During thermal testing to temperatures up to 500 °C, the embedded thermocouples read consistently with one another and deviated only slightly from the readings of a nonembedded thermocouple located within the furnace. This slight discrepancy was most likely due to differences in the thermal time constants for a nonembedded thermocouple vs. a thermocouple embedded in a solid SS316 block. The results presented in this report will serve as the foundation for future work that will focus on embedding sensors in relevant TCR reactor components and eventually testing those components under neutron irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2

As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.

17 WIND ENERGY↗
DOE OSTI2024

Isolated Single Metal Atoms Supported on Silica for One Step Non-Oxidative Methane Upgrading to Hydrogen and Value-Added Hydrocarbons

Natural gas in the United States offers substantial economic opportunities due to its abundance but its transportation is challenging because its primary component, methane (CH 4 ), does not liquefy at ambient temperature and typical pressures. As a result, a significant portion of natural gas is either used for heat, flared in remote locations, or remains unutilized, presenting a lost economic opportunity and an environmental harm. Converting natural gas to larger hydrocarbons in an economically competitive manner would enable transportation of products and further boost the economy and reduce environmental footprint. Our research goal is to enable efficient non-oxidative methane conversion (NMC) via catalyst innovation to convert CH 4 in one-step to olefins and aromatics and hydrogen (H 2 ) co-product. The catalysts are made of supported single metal atoms and operated at medium-high temperatures. The single metal atoms achieve methane activation by heterogeneous surface dehydrogenation to generate a hydrocarbon pool and importantly limit coke formation. The integration of novel single atom catalysts in a short contact time microreactor enable unprecedented NMC performance that could lead to economically-feasible, distributed natural gas upgrading by advanced manufacturing and process intensification. Our innovated catalyst and reactor technology promise to tap into previously uneconomic natural gas resources, such as stranded, vented, and flared methane.

03 NATURAL GAS↗
DOE OSTI2020

Investigating Porous Media for Relief Printing Using Micro-Architected Materials

Advances in printed electronics are predicated on the integration of sophisticated printing technologies with functional materials. Although scalable manufacturing methods, such as letterpress and flexographic printing, have significant history in graphic arts printing, functional applications require sophisticated control and understanding of nanoscale transfer of fluid inks. In this paper, a versatile platform is introduced to study and engineer printing forms, exploiting a microscale additive manufacturing process to design micro-architected materials with controllable porosity and deformation. Building on this technology, controlled ink transfer for submicron functional films is demonstrated. The design freedom and high-resolution 3D control afforded by this method provide a rich framework for studying mechanics of fluid transfer for advanced manufacturing processes.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Bi-metallic Nanoparticle Synthesis for Advanced Manufactured Melt Wires

Science Undergraduate Laboratory Internship (SULI) Program Report: Additive manufacturing (AM) based on direct-write technologies has emerged as the predominant method for the fabrication of passive sensors for the harsh operating environments seen in a nuclear reactor. Through the modification of previous methods, Idaho National Laboratory and Villanova University have improved the synthesis process for AM feedstock, which will allow for the improvement of advanced nuclear sensors and instrumentation. A major part of this work includes the synthesis process of relevant AM compatible feedstock to support the development, fabrication, and testing of AM sensors for peak temperature detection. For this report, bismuth, bismuth/platinum, tin, tin/silver, tin/zinc, indium, and indium/silver bi-metallic nanoparticles were synthesized using the polyol method, which will enhance temperature sensitivity and allow for miniaturization. To characterize the synthesized nanoparticles, we used x-ray fluorescence to evaluate the elemental composition of the nanoparticles and differential scanning calorimetry and thermogravimetric analysis to determine the melting point and mass loss of the samples. Results show that bi-metallic nanoparticles are a viable option for the fabrication of high-resolution AM melt wires. The temperature sensitivity can be brought to within 5°C and melt wires can be fabricated that are in the micrometer scale. This will expand the range of irradiation experiments melt wires can be used for and the measured temperature will be significantly more accurate.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Transforming Energy Through Computational Excellence: High-Performance Computing for Energy Innovation

The challenges associated with energy efficiency of manufacturing and advanced materials often cannot be addressed through experimentation alone, whether because of scale, complexity, or practicality. High-performance computing (HPC) enables fast tackling of these challenges in the manufacturing sector - vital to achieving net-zero carbon emissions by 2050. The National Renewable Energy Laboratory (NREL) and industry partners leverage HPC to apply advanced modeling, simulation, and data analysis to improve manufacturing efficiency, explore new materials for energy applications, and develop technologies to manage carbon across the life cycle. From improving additive manufacturing processes to increasing the energy efficiency of jet-engine components, advanced computing can help manage emissions produced by manufacturing in a wide variety of ways.

advanced materials↗
DOE OSTI2020

Accomplishments and Mid-Year Performance Report: Wind Energy Program Fiscal Year 2020

Through transformative science and innovation, the U.S. Department of Energy's (DOE's) National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory's (NREL's) Flatirons Campus helps lead the way to a sustainable energy future that powers America with significant levels of reliable, low-cost, and accessible wind energy. Since 1976, NREL has provided an ideal environment for the research and development (R&D) of advanced energy technologies through: Wind energy resource assessments, World-class research facilities, High-performance computing and modeling, Data and technology analysis, Manufacturing breakthroughs, Environmental analysis and wildlife conservation efforts, Education and training programs for a future workforce. These activities enable the innovations needed to advance U.S. wind systems, address market and deployment barriers, and drive down the cost of wind energy with more efficient, more reliable, and more predictable wind energy systems. This report provides an overview of the achievements NREL delivered on behalf of DOE's Wind Energy Technologies Office (WETO) and other partners during the first and second quarters of Fiscal Year (FY) 2020.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2024

Advanced Manufacturing and Materials for Hydropower Strategy

Advanced manufacturing and materials (AMM) are revolutionizing how the energy sector is built, and the hydropower industry stands to benefit greatly from these new opportunities. The mission of the U.S. Department of Energy’s (DOE) Water Power Technologies Office (WPTO) is to enable research, development, and testing of new technologies to advance marine energy as well as next-generation hydropower and pumped storage systems for a flexible and reliable grid. This strategic plan outlines how WPTO can support AMM technologies for hydropower and pumped storage applications.

13 HYDRO ENERGY↗