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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

Planar slicing for nonextrusion AM processes

Extrusion-based AM processes, including material extrusion and directed energy deposition, construct objects by continuously depositing a relatively small amount of molten feedstock to a specific location. Nonextrusion AM processes, on the other hand, tend to form each layer by linearly or areally projecting either energy onto a vat of photocurable liquid or a binding agent into a bed of loose powder. Such systems vary significantly from extrusion-based AM processes but do share similarities. The general approach to path planning is the same, but nonextrusion processes typically favor the use of bitmap representations, instead of polygons, for pathing computation and do not use a g-code file to command the printer. In this chapter, a high-level discussion of these differences will be covered.

Macdonald, Eric↗

Material properties and mechanical behaviour of functionally graded steel produced by wire-arc additive manufacturing

Metal Big Area Additive Manufacturing is an additive manufacturing technique based on Gas Metal Arc Welding (GMAW) with the option to use many shielding gases, and materials. The system is equipped with a dual torch design allowing for printing different materials; in our study, AISI 410 stainless steel and AWS ER70S-6 mild steel are both printed in the same component. Different print strategies were designed to highlight changes in material and mechanical properties. Deformation behaviour of a materials’ interface was analysed by two-dimensional digital image correlation of uniaxial tensile specimens in displacement-controlled tests. Instances of non-homogeneous local strains adjacent to the interface are observed, as well as variability in mechanical behaviour and microstructure based on location within the print. Optical and electron microscopy are used to evaluate three microstructural zones in a 5 mm range of the interface between mild steel and stainless steel. Areas far from the interface produced polygonal ferrite and pearlite, while areas close to the interface produced acicular ferrite and bainite. Chromium redistribution profiles are dependent on the print strategy used, as shown by scanning electron microscopy with Energy dispersive spectroscopy. Evidence produced via electron backscatter diffraction is shown to support the argument that transformation induced plasticity is not the cause for the non-homogeneous deformation.

36 MATERIALS SCIENCE↗

Variable resolution Poisson-disk sampling for meshing discrete fracture networks

Here, we present the near-Maximal Algorithm for Poisson-disk Sampling (nMAPS) to generate point distributions for variable resolution Delaunay triangular and tetrahedral meshes in two and three-dimensions, respectively. nMAPS consists of two principal stages. In the first stage, an initial point distribution is produced using a cell-based rejection algorithm. In the second stage, holes in the sample are detected using an efficient background grid and filled in to obtain a near-maximal covering. Extensive testing shows that nMAPS generates a variable resolution mesh in linear run time with the number of accepted points. We demonstrate nMAPS capabilities by meshing three-dimensional discrete fracture networks (DFN) and the surrounding volume. The discretized boundaries of the fractures, which are represented as planar polygons, are used as the seed of 2D-nMAPS to produce a conforming Delaunay triangulation. The combined mesh of the DFN is used as the seed for 3D-nMAPS, which produces conforming Delaunay tetrahedra surrounding the network. Under a set of conditions that naturally arise in maximal Poisson-disk samples and are satisfied by nMAPS, the two-dimensional Delaunay triangulations are guaranteed to only have well-behaved triangular faces. While nMAPS does not provide triangulation quality bounds in more than two dimensions, we found that low-quality tetrahedra in 3D are infrequent, can be readily detected and removed, and a high-quality balanced mesh is produced.

97 MATHEMATICS AND COMPUTING↗

Scaled boundary cubature scheme for numerical integration over planar regions with affine and curved boundaries

This paper introduces the scaled boundary cubature (SBC) scheme for accurate and efficient integration of functions over polygons and two-dimensional regions bounded by parametric curves. Over two-dimensional domains, the SBC method reduces integration over a region bounded by m curves to integration over m regions (referred to as curved triangular regions), where each region is bounded by two line segments and a curve. With proper (counterclockwise) orientation of the boundary curves, the scheme is applicable to convex and nonconvex domains. Additionally, for star-convex domains, a tensor-product cubature rule with positive weights and integration points in the interior of the domain is obtained. If the integrand is homogeneous, we show that this new method reduces to the homogeneous numerical integration scheme; however, the SBC scheme is more versatile since it is equally applicable to both homogeneous and non-homogeneous functions. This paper also introduces several methods for smoothing integrands with point singularities and near-singularities. When these methods are used, highly efficient integration of weakly singular functions is realized. Finally, the SBC method is applied to a number of benchmark problems, which reveal its broad applicability and superior performance (in terms of time to generate a rule and accuracy per cubature point) when compared to existing methods for integration.

42 ENGINEERING↗

Geothermal Play Fairway Analysis, Part 2: GIS methodology

Play Fairway Analysis (PFA) in geothermal exploration originates from a systematic methodology developed within the petroleum industry and is based on a geologic, geophysical, and hydrologic framework of identified geothermal systems. We tailored this methodology to study the geothermal resource potential of the Snake River Plain and surrounding region, but it can be adapted to other geothermal resource settings. We adapted the PFA approach to geothermal resource exploration by cataloging the critical elements controlling exploitable hydrothermal systems, establishing risk matrices that evaluate these elements in terms of both probability of success and level of knowledge, and building a code-based ‘processing model’ to process results. A geographic information system was used to compile a range of different data types, which we refer to as elements (e.g., faults, vents, heat flow, etc.), with distinct characteristics and measures of confidence. Discontinuous discrete data (points, lines, or polygons) for each element were transformed into continuous interpretive 2D grid surfaces called evidence layers. Because different data types have varying uncertainties, most evidence layers have an accompanying confidence layer which reflects spatial variations in these uncertainties. Risk layers, as defined here, are the product of evidence and confidence layers, and are the building blocks used to construct Common Risk Segment (CRS) maps for heat, permeability, and seal, using a weighted sum for permeability and heat, but a different approach with seal. CRS maps quantify the variable risk associated with each of these critical components. In a final step, the three CRS maps were combined into a Composite Common Risk Segment (CCRS) map, using a modified weighted sum, for results that reveal favorable areas for geothermal exploration. Additional maps are also presented that do not mix contributions from evidence and confidence (to allow an isolated view of evidence and confidence), as well as maps that calculate favorability using the product of components instead of a weighted sum (to highlight where all components are present). Our approach helped to identify areas of high geothermal favorability in the western and central Snake River Plain during the first phase of study and helped identify more precise local drilling targets during the second phase of work. By identifying favorable areas, this methodology can help to reduce uncertainty in geothermal energy exploration and development.

15 GEOTHERMAL ENERGY↗

A cell-centered AMR-ALE framework for 3D multi-material hydrodynamics. Part I: Lagrangian and indirect Euler AMR algorithms

Many applications of physics and engineering involve wide ranges of time and spatial scales. The numerical simulation of localized small scales such as shock waves and material interfaces requires a large number of computational cells in these regions. For these applications, Lagrangian and Arbitrary-Lagrangian-Eulerian (ALE) related methods are engaging since the moving mesh feature naturally brings mesh cells on shock discontinuities and material interfaces are carefully captured. In addition, Adaptive-Mesh-Refinement (AMR) strategies aim to optimize computational resources by concentrating finer mesh cells only in areas of interest while using coarser cells elsewhere. A key but challenging AMR requirement consists in efficiently distributing the computational effort to achieve high accuracy without the prohibitive computational costs associated with uniformly fine grids. Here, in this document, the coupling of the p4est AMR library with a cell-centered Lagrangian scheme is presented with the goal to perform reliable 3D Lagrangian-AMR and indirect Euler-AMR multi-material simulations. In particular, it is shown that starting from a 3D indirect ALE code, the memory management and load balancing requirements can be delegated to an external library (here the p4est library) to unlock ALE-AMR capabilities. First, we present a strategy to transcribe the octant-based connectivity of the 3D AMR framework with that of an unstructured mesh of polygonal cells used in Lagrangian hydrodynamics. Then, we show how refinement and coarsening operations must be adapted to the particular Lagrangian framework to ensure the conservation of volume during those steps. Finally, several numerical test cases are presented that demonstrate the capabilities of the Lagrangian-AMR and indirect Euler-AMR algorithms.

3D cell-centered Lagrangian numerical scheme↗

Hourglass control in staggered-grid hydrodynamics using virtual element stabilization techniques

Numerical simulations using the staggered-grid hydrodynamics (SGH) discretization suffer from hourglass instabilities. In this work, we develop a stabilization method to suppress the hourglass instabilities using techniques from the virtual element method (VEM). The stiffness matrix of the VEM consists of two terms: the consistency matrix which is rank deficient and the stability matrix. Here, we first show that in two dimensions and on general polygons, the stiffness matrix of the SGH is identical to the consistency matrix of the linear VEM for both the diffusion equation and the linear elasticity equation. These analyses explain the origin of the hourglass instabilities of the SGH discretization method, and establish a theoretical foundation for our proposed stabilization method by augmenting the stiffness matrix of the SGH discretization using the VEM stability matrix. Then, we present numerical examples using Lagrangian SGH simulations. The numerical experiments demonstrate that the proposed VEM stabilization method is effective at eliminating hourglass modes in the SGH discretization.

97 MATHEMATICS AND COMPUTING↗

Effect of heat treatment on the microstructure of medium burn-up U-Mo monolithic fuel foils

Using scanning electron microscopy (SEM), this study evaluates the microstructure evolution of U-Mo fuel foils made with and without heat treatment at medium burn-up (of approximately 5 x 10 21 f/cm 3 ). The impact of annealing treatments on critical microstructural properties of the U-Mo fuel foils, including porosity, grain structure, Mo homogeneity, and fuel interaction with the Zr interlayer, was examined using large area lift outs (LALOs). The heat-treated specimens presented less grain refining at these burnups when compared to the un-heated specimens. Grain refinement was associated with porosities and fission products precipitation. Heat treatment can reduce fuel swelling during irradiation. Chemical inhomogeneity (Mo banding) was found to persist in the un-heated samples but was not present in the heat-treated samples. Thus, heat-treated U-Mo foils allows for more predictable fuel behavior under irradiation with respect to un-heated foils. The U-Mo and Zr interaction layer appears to be thicker and more continuous in the heat-treated sample which has been associated with stronger interface integrity during irradiation, as also observed in previous studies. These observations may indicate an overall improved performance of heat-treated fuel foil in a reactor. Further, the effect of local burn-up on grain size/refinement and porosities in each LALO specimen, sampled from different positions in the fuel foil, was difficult to analyze due to the large standard deviation of these parameters. Finally, evidence of grain refinement by polygonization may be present in these specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Nondestructive ultrasonic characterization of a triple-weld-bead wire arc additively manufactured ER70S-6 S-curved wall

Understanding build-scale microstructural variation in wire arc additive manufacturing (WAAM) of low-carbon steels is essential for ensuring consistent structure–property relationships throughout large components. Conventional destructive characterization techniques, such as scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), are time-intensive and limited to localized regions, making comprehensive evaluation of large WAAM structures challenging. In this study, a nondestructive ultrasonic approach was employed to characterize a 252 mm tall ER70S-6 S-curved WAAM wall produced using a triple-bead deposition strategy. Optical and SEM analysis revealed a repeating dual-region microstructure consisting of uniform polygonal ferrite at melt pool centers and heterogeneous ferrite with coarse and fine grains near melt pool boundaries, attributed to cyclic thermal conditions. Longitudinal ultrasonic backscatter imaging was used to evaluate the continuity of this periodicity along the full build height. The ultrasonic response exhibited a consistent repeating pattern that correlated with the observed layer-wise microstructural variation. X-ray computed tomography confirmed the absence of detectable porosity, indicating that ultrasonic contrast is primarily governed by grain morphology. Overall, the results indicate that longitudinal backscatter ultrasound is a promising nondestructive characterization technique for validating microstructural variations along the s-curved WAAM wall, with significant potential for microstructure optimization and process control.

36 MATERIALS SCIENCE↗

Thermally induced structural evolution and nanoscale interfacial dynamics in Bi-Sb-Te layered nanostructures

Layered chalcogenides, including Bi-Sb-Te ternary alloys and heterostructures, are renowned as thermoelectric and topological insulators and have recently been highlighted as plasmonic building blocks beyond noble metals. Here, we conduct joint in situ transmission electron microscopy and density functional theory calculations to investigate the temperature-dependent nanoscale dynamics and interfacial properties, identifying the role of native defects and edge configurations in the anisotropic sublimation of Bi 2 Te 3 -Sb 2 Te 3 heterostructures and Sb 2-x Bi x Te 3 alloys. We report structural dynamics, including edge evolution, layer-by-layer sublimation, and the formation and coalescence of thermally induced polygonal nanopores. These nanopores are initiated by preferential dissociation of tellurium, reducing thermal stability in heterostructures. Triangular and quasi-hexagonal configurations dominate nanopore structures in heterostructures. Our calculations reveal antisite defects (Te Sb and Te Bi ) as key players in defect-assisted sublimation. These findings enhance our understanding of nanoscale dynamics and assist in designing tunable low-dimensional chalcogenides.

Bi2Te3-Sb2Te3 heterostructure↗

Spherical time-encoded radiation imaging simulations

Radiation source localization is important for nuclear nonproliferation and can be obtained using time-encoded imaging systems with unsegmented detectors. A scintillation crystal can be used with a moving coded-aperture mask to vary the detected count rate produced from radiation sources in the far field. The modulation of observed counts over time can be used to reconstruct an image with the known coded-aperture mask pattern. Current time-encoded imaging systems incorporate cylindrical coded-aperture masks and have limits to their fully coded imaging field-of-view. This work focuses on expanding the field-of-view to 4π by using a novel spherical coded-aperture mask. A regular icosahedron is used to approximate a spherical mask. This icosahedron consists of 20 equilateral triangles; the faces of which are each subdivided into four equilateral triangle-shaped voxels which are then projected onto a spherical surface, creating an 80-voxel coded-aperture mask. Furthermore, these polygonal voxels can be made from high-Z materials for gamma-ray modulation and/or low-Z materials for neutron modulation. In this work, we present Monte Carlo N-Particle (MCNP) simulations and simple models programmed in Mathematica to explore image reconstruction capabilities of this 80-voxel coded-aperture mask.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Linearized modeling and optimization of shared mooring systems

Shared mooring systems, where adjacent platforms are tethered directly to each other, can reduce anchor quantities and mooring line lengths in a floating array but also introduce new modeling and design challenges. This paper presents and demonstrates a first-order approach to modeling and designing shared mooring systems that simplifies these challenges. We formulate a general, linearized model for the force-displacement response of shared mooring systems, including inter-platform couplings. Using this linearization, we realize significant simplifications to the shared mooring system design problem and propose a corresponding design optimization approach. Finally, we demonstrate the complete approach on a variety of shared-mooring floating wind farm layouts with generic design assumptions and constraints. Some fundamental observations about shared mooring systems can be made from the results. Polygonal array layouts with perpendicular anchor positions appear to maximize shared mooring system efficiency. Also, arrays with greater levels of sharing tend to exhibit larger deviations in offsets between platforms. Overall, the results show how the linearized approach can be applied to efficiently evaluate and systematically optimize preliminary shared mooring system designs.

17 WIND ENERGY↗

Satellite-based aerosol optical depth estimates over the continental U.S. during the 2020 wildfire season: Roles of smoke and land cover

Wildfires produce smoke that can affect an area >1000 times the burn extent, with far-reaching human health, ecologic, and economic impacts. Accurately estimating aerosol load within smoke plumes is therefore crucial for understanding and mitigating these impacts. We evaluated the effectiveness of the latest Collection 6.1 MODIS Multi-Angle Implementation of Atmospheric Correction (MAIAC) algorithm in estimating aerosol optical depth (AOD) across the U.S. during the historic 2020 wildfire season. We compared satellite-based MAIAC AOD to ground-based AERONET AOD measurements during no-, light-, medium-, and heavy-smoke conditions identified using the Hazard Mapping System Fire and Smoke Product. This smoke product consists of maximum extent smoke polygons digitized by analysts using visible band imagery and classified according to smoke density. We also examined the strength of the correlations between satellite- and ground-based AOD for major land cover types under various smoke density levels. MAIAC performed well in estimating AOD during smoke-affected conditions. Correlations between MAIAC and AERONET AOD were strong for medium- (r = 0.91) and heavy-smoke (r = 0.90) density, and MAIAC estimates of AOD showed little bias relative to ground-based AERONET measurements (normalized mean bias = 3 % for medium, 5 % for heavy smoke). During two high AOD, heavy smoke episodes, MAIAC underestimated ground-based AERONET AOD under mixed aerosol (i.e., smoke and dust; median bias = −0.08) and overestimated AOD under smoke-dominated (median bias = 0.02) aerosol. MAIAC most overestimated ground-based AERONET AOD over barren land (mean NMB = 48 %). Our findings indicate that MODIS MAIAC can provide robust estimates of AOD as smoke density increases in coming years. Increased frequency of mixed aerosol and expansion of developed land could affect the performance of the MAIAC algorithm in the future, however, with implications for evaluating wildfire-associated health and welfare effects and air quality standards.

54 ENVIRONMENTAL SCIENCES↗

Precise Synthesis of 4.75 V-Tolerant LiCoO 2 with Homogeneous Delithiation and Reduced Internal Strain

The rapid advancements in 3C electronic devices necessitate an increase in the charge cutoff voltage of LiCoO 2 to unlock a higher energy density that surpasses the currently available levels. However, the structural devastation and electrochemical decay of LiCoO 2 are significantly exacerbated, particularly at ≥4.5 V, due to the stress concentration caused by more severe lattice expansion and shrinkage, coupled with heterogeneous Li + intercalation/deintercalation reactions. Herein, employing the molten-salt synthesis technique, we propose a universal morphology-shaping strategy to attain bulk reaction homogeneity and reduce internal strains, even at extremely high charge voltages. The newly designed flattened polygon prismlike LiCoO 2 (P-LCO) particle, featuring a regular symmetrical arrangement along the c-axis, demonstrates a more homogeneous Li + extraction/insertion reaction, which results in a restrained transformation to detrimental O1 phase and reduced variation in lattice volume throughout the (de)lithiation processes. This benefits the mitigation of the local stress accumulation misfit dislocations and particle cracking, ultimately maintaining the mechanical stability of the cathode. Consequently, P-LCO is capable of breaking the voltage ceiling and exhibits exceptional long-term cycling capability at an ultrahigh voltage of 4.75 V. In conclusion, this work offers a brand-new perspective for the rational design of cathode morphology to address capacity deterioration caused by inhomogeneous delithiation and internal strain, thus inspiring the development of high-energy-density cathodes with improved durability.

36 MATERIALS SCIENCE↗

Simulated Hydrological Dynamics and Coupled Iron Redox Cycling Impact Methane Production in an Arctic Soil

The fate of organic carbon (C) in permafrost soils is important to the climate system due to the large global stocks of permafrost C. Thawing permafrost can be subject to dynamic hydrology, making redox processes an important factor controlling soil organic matter (SOM) decomposition rates and greenhouse gas production. In iron (Fe)-rich permafrost soils, Fe(III) can serve as a terminal electron acceptor, promoting anaerobic respiration of SOM and increasing pH. Current large-scale models of Arctic C cycling do not include Fe cycling or pH interactions. Here, a geochemical reaction model was developed by coupling Fe redox reactions and C cycling to simulate SOM decomposition, Fe(III) reduction, pH dynamics, and greenhouse gas production in permafrost soils subject to dynamic hydrology. In this study we parameterized the model using measured CO 2 and CH 4 fluxes as well as changes in pH, Fe(II), and dissolved organic C concentrations from oxic and anoxic incubations of permafrost soils from polygonal permafrost sites in northern Alaska, United States. In simulations of repeated oxic-anoxic cycles, Fe(III) reduction during anoxic periods enhanced CO 2 production, while the net effect of Fe(III) reduction on cumulative CH 4 fluxes depended on substrate C availability. With lower substrate availability, Fe(III) reduction decreased total CH 4 production by further limiting available substrate. With higher substrate availability, Fe(III) reduction enhanced CH 4 production by increasing pH. Our results suggest that interactions among Fe-redox reactions, pH and methanogenesis are important factors in predicting CH 4 and CO 2 production as well as SOM decomposition rates in Fe-rich, frequently waterlogged Arctic soils.

54 ENVIRONMENTAL SCIENCES↗

An Examination of Water-Related Melt Processes in Arctic Snow on Tundra and Sea-Ice

From April through June in 2019 and 2022, we monitored snow melt at three sites near Utqiaġvik, Alaska. Along 200-m lines we measured snow depth, density, stratigraphy, snow-covered area, and spectral albedo. Site 1 (ARM) was sloped tundra drained by water tracks. Site 2 (BEO) was flat polygonal tundra. Site 3 (ICE) was on undeformed landfast sea ice. All three sites were within a 6 km radius. Despite similar pre-melt snow distributions and weather, the melt progression differed markedly between sites. In 2019, by mid-melt, there was 40% less snow-covered area at ARM versus ICE, and 34% less snow-covered area at ARM versus BEO. The 2022 melt started 2 weeks later than in 2019 and was rapid, so smaller differences in snow-covered areas developed. In both years meltout dates varied by up to 25 days between sites, and more than 20 days within sites, with melt rates at locations only meters apart differing by up to a factor of seven. This melt diachroneity led to highly heterogeneous meltout patterns at all three sites. Our measurements and observations indicate that, in addition to reductions in snow reflective properties and wind-driven heat advection, the fate of meltwater plays a key role in producing melt diachroneity. We identify seven snow-water mechanisms that can enhance or inhibit melt rates, all largely controlled by the local topography and the nature of the substrate. These mechanisms are important because the most rapid changes in albedo coincide with the peak of water-snow melt interactions.

54 ENVIRONMENTAL SCIENCES↗

Water Mass Transformation Budgets in Finite‐Volume Generalized Vertical Coordinate Ocean Models

Water Mass Transformation (WMT) theory provides conceptual tools that in principle enable innovative analyses of numerical ocean models; in practice, however, these methods can be challenging to implement and interpret, and therefore remain under-utilized. Our aim is to demonstrate the feasibility of diagnosing all terms in the water mass budget and to exemplify their usefulness for scientific inquiry and model development by quantitatively relating water mass changes, overturning circulations, boundary fluxes, and interior mixing. We begin with a pedagogical derivation of key results of classical WMT theory. We then describe best practices for diagnosing each of the water mass budget terms from the output of Finite-Volume Generalized Vertical Coordinate (FV-GVC) ocean models, including the identification of a non-negligible remainder term as the spurious numerical mixing due to advection scheme discretization errors. We illustrate key aspects of the methodology through the analysis of a polygonal region of the Greater Baltic Sea in a regional demonstration simulation using the Modular Ocean Model v6 (MOM6). We verify the convergence of our WMT diagnostics by brute-force, comparing time-averaged (“offline”) diagnostics on various vertical grids to timestep-averaged (“online”) diagnostics on the native model grid. Finally, we briefly describe a stack of xarray-enabled Python packages for evaluating WMT budgets in FV-GVC models (culminating in the new xwmb package), which is intended to be model-agnostic and available for community use and development.

54 ENVIRONMENTAL SCIENCES↗