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At least 325 records · Page 18

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NASA NTRS2003

Contact Angle of Drops Measured on Nontransparent Surfaces and Capillary Flow Visualized

The spreading of a liquid on a solid surface is important for various practical processes, and contact-angle measurements provide an elegant method to characterize the interfacial properties of the liquid with the solid substrates. The complex physical processes occurring when a liquid contacts a solid play an important role in determining the performance of chemical processes and materials. Applications for these processes are in printing, coating, gluing, textile dyeing, and adhesives and in the pharmaceutical industry, biomedical research, adhesives, flat panel display manufacturing, surfactant chemistry, and thermal engineering.

Chao, David F.↗

DOE OSTI2019

Quantifying adoption rates and energy savings over time for advanced energy-efficient manufacturing technologies

Energy-efficient manufacturing technologies can reduce energy consumption and lower operating costs for manufacturing facilities, but up-front costs and increased process complexity frequently lead to manufacturers being reluctant to adopt such technologies. To avoid overestimating the benefits of advanced energy-efficient manufacturing technologies, it is necessary to account for how quickly and how widely the technology will be adopted by manufacturers. This work develops a method for estimating manufacturing technology adoption rates using quantitative technology characteristics including energetic, economic, and technical criteria that capture both incentives (such as energy and cost savings) and disincentives (such as increased process complexity) for technology adoption. This method is unique in that it can be applied before or after a technology reaches the market; other adoption rate estimation methods require sales data and can only be applied post-market. Eleven technology characteristics are considered, with each characteristic weighted to reflect its impact on the overall technology adoption rate. Technology characteristic data is used to estimate model parameters for the Bass diffusion curve, which quantifies the change in the number of new technology adopters in a population over time. Finally, energy savings at the sector level are calculated over time by multiplying the number of new technology adopters at each time step with the technology’s facility-level energy savings. The proposed method is demonstrated with an application to glass industry manufacturing technologies using technology data obtained from the U.S. Department of Energy's 2017 bandwidth study. The potential energy savings for each technology and the rate at which each technology is adopted in the sector are quantified and used to identify the technologies which offer the greatest cumulative sector-level energy savings over a period of 20 years.

advanced manufacturing↗

DOE OSTI2020

Mechanisms of Al3+ dimerization in alkaline solutions

The molecular speciation of aluminum (Al3+) in alkaline solutions is fundamental to its precipitation chemistry within a number of industrial applications that include ore renement and industrial processing of Al wastes. Under these conditions, Al3+ is predominantly Al(OH) {4 , while at high [Al] dimeric species also known to form. To date, the mechanism of dimer formation remains unclear and it is likely infuenced by complex ion ion interactions. In the present work, we investigate the role of ion pairing and a suite of potential dimerization pathways using a three-pronged approach that consists of density functional theory-based molecular dynamics (DFTMD), static DFT calculations (sDFT) and semi-empirical density functional tight binding molecular dynamics (SEMD). Specic cation eects imparted by the background electrolyte cations Na+, Li+ and K+ have been examined. Our simulations predict that when the Al species are ion paired with either cation the formation of the oxo-bridged Al2O(OH) 2{6 is favored with respect to the dihydroxo-bridged Al2(OH) 2{8 , in agreement with previousspectroscopic work. The formation of both dimers rst proceeds by bridging of two monomeric units via one hydroxo ligand, leading to a labile Al2(OH) 2{8 isomer. The eect of contact ion pairing of Li+ and K+ on the dimerization energetics is distinctly more favorable than that of Na+, which may have an impact on further ligomerization.

Pouvreau, Maxime↗

DOE OSTI2020

Roles of Carburization and Oxidation on Transition-Metal Catalyzed Surface Reactions

Many industrial chemical transformation processes are based on reactions catalyzed by transition metals. In some cases the nano-size particles used as catalysts are synthesized simultaneously or right before the initiation of the main catalytic reaction. Synthesis treatments involve complex processes such as reductions followed by calcinations in oxygenated environments coupled to the presence of gases used for the main reaction. Synthesis details are crucial because they have important consequences on the catalyst shape, size, and chemical composition, and may also affect the structure and composition of the catalyst support. All these effects may alter the main catalyzed reaction in unexpected ways. This work focuses on the synthesis of the overall catalytic system that includes catalyst and support taking place in parallel with the initial stages of the main catalyzed reaction. Two important processes are characterized: carburization and oxidation of the transition metal catalyst during synthesis or initial stages of the main reaction. The objective is to understand how the coking mechanism coupled to surface oxidation and changes in the substrate influence the dry reforming of methane taken as a model reaction. The approach uses first principles computational methods to investigate the catalyst synthesis and characterization and catalytic reaction mechanisms. These studies are complemented with experimental characterization done by the group of Dr. Renu Sharma at the National Institute of Standards and Technology (unfunded collaborator) using high resolution transmission electron microscopy. Specific goals are to identify the role of the synthesis process on the initial nanocatalyst structure and composition, and to determine how that structure and composition may evolve after being exposed to the reactants atmosphere. These studies facilitate a systematic analysis of conditions where the nanoparticle composition can be optimized regarding activity and stability. Moreover, the fundamental study of catalyst/support interactions yields valuable insights for other catalytic processes and is a first step toward controlled nanocatalyst synthesis.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Roughrider Carbon Storage Hub (Final Report)

The Roughrider Carbon Storage Hub was a 2-year project (October 2023 – September 2025) conducted by the Energy & Environmental Research Center (EERC) focused on advancing the feasibility of a commercial-scale carbon dioxide (CO 2 ) geologic storage hub in McKenzie County, North Dakota. The project’s objective was to investigate the potential that stacked storage complexes (multiple deep saline formations) can safely and economically store at least 50 million tonnes of CO 2 within 30 years. The captured CO 2 would be sourced from industrial emitters including project partner ONEOK, Inc.’s gas-processing plants and a planned gas-to-liquids facility. Drilling of the Roughrider 1 stratigraphic test well (14,979-ft total depth) was completed in November 2024. The wellbore intersected four candidate storage formations: Inyan Kara, Broom Creek, Mission Canyon, and Black Island–Deadwood. Operational challenges, including a stuck drill string, were resolved without long-term impact. A comprehensive logging and coring program was conducted, followed by successful well abandonment and site reclamation. Over 660 ft of 4-in. whole core was retrieved. Core plug samples were processed and analyzed for petrophysical and geochemical properties. Results confirmed promising porosity and permeability in the Inyan Kara and Broom Creek Formations and removal of the Mission Canyon and Black Island–Deadwood horizons from further investigation. Data derived from the logging and coring program were used to improve initial geologic models built from legacy data. CO 2 injection simulations showed that the Inyan Kara alone can feasibly store the target mass of CO 2 . Because of subtle differences in geologic structure and porosity trends between the formations, a stacked storage scenario using the Broom Creek and Inyan Kara Formations resulted in a larger overall plume area than using the Inyan Kara alone. Preliminary CO 2 pipeline routes from the industrial sources were mapped utilizing existing rights of way and evaluated for capacity and cost using U.S. Department of Energy Office of Fossil Energy and Carbon Management/National Energy Technology Laboratory models and U.S. Environmental Protection Agency emissions data. Integrating capture, transport, and storage cost estimates with policy incentives (e.g., 45Q credits) provided a total cost-per-ton analysis. Results indicate that the small scale of the volumes to be transported over the cumulative large distances does not support the project’s financial viability. However, the groundwork laid during this project from geological, regulatory, and social perspectives positions the Roughrider hub site as a promising candidate for commercial carbon storage in North Dakota, especially if the economy of scale is introduced for CO 2 transportation to the hub site.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1992

Uncertainty management by relaxation of conflicting constraints in production process scheduling

Mathematical-analytical methods as used in Operations Research approaches are often insufficient for scheduling problems. This is due to three reasons: the combinatorial complexity of the search space, conflicting objectives for production optimization, and the uncertainty in the production process. Knowledge-based techniques, especially approximate reasoning and constraint relaxation, are promising ways to overcome these problems. A case study from an industrial CIM environment, namely high-grade steel production, is presented to demonstrate how knowledge-based scheduling with the desired capabilities could work. By using fuzzy set theory, the applied knowledge representation technique covers the uncertainty inherent in the problem domain. Based on this knowledge representation, a classification of jobs according to their importance is defined which is then used for the straightforward generation of a schedule. A control strategy which comprises organizational, spatial, temporal, and chemical constraints is introduced. The strategy supports the dynamic relaxation of conflicting constraints in order to improve tentative schedules.

Dorn, Juergen↗

DOE OSTI2017

The Off-Site Source Recovery Program Capabilities in Recovering Transuranic Sealed Sources - 17599

Over the past 16 years, the mission of the Off-Site Source Recovery Program (OSRP) has been recovering disused radioactive sealed sources in the interest of national security, public health and safety. This program, which is sponsored by the National Nuclear Security Administration's Office of Global Material Security's Office of Radiological Security, is managed at Los Alamos National Laboratory and Idaho National Laboratory and has recovered sources worldwide. To date, OSRP has recovered more than 38,000 sources from over 1,300 locations worldwide. Since its inception, OSRP has grown from recovering only sealed sources containing one transuranic (TRU) isotope, Pu-239, in the early days of the program, to recovering sealed sources containing several other TRU and non-TRU isotopes. Primarily, OSRP's mission includes Pu-238, Pu-239, Am-241, Cf-252, Cm-244, Sr-90, Cs-137, Co-60, Ir-192 and Ra-226 sources that are US-origin, defense related and not commercially disposable. Over the lifetime of this program the types of recoveries performed have expanded from a single site to multi-site round-up recoveries. An additional approach, referred to as self-ship recoveries, is also used in cases where only a few sources may be present at a licensee's site. In these situations, the licensee ships their source(s) to an OSRP staging facility for ultimate consolidation and disposal. OSRP recovers sources from many types of licensees, with the majority of sources being removed from industry, universities and hospitals. These include sealed sources used in industrial radiological devices like moisture-density gauges and thickness gauges, medical devices such as blood irradiators and radiotherapy devices and sealed sources from nuclear power plants, among others. The recovery and management of sealed sources is a complex process covering multidisciplinary areas, including source construction, characteristics of the radioactive material, source packaging and transportation per DOT regulations, safe and secure storage, and final disposition per waste acceptance criteria of repository sites. (authors)

07 ISOTOPE AND RADIATION SOURCES↗

NASA NTRS2002

A System for Planning Ahead

A software system that uses artificial intelligence techniques to help with complex Space Shuttle scheduling at Kennedy Space Center is commercially available. Stottler Henke Associates, Inc.(SHAI), is marketing its automatic scheduling system, the Automated Manifest Planner (AMP), to industries that must plan and project changes many different times before the tasks are executed. The system creates optimal schedules while reducing manpower costs. Using information entered into the system by expert planners, the system automatically makes scheduling decisions based upon resource limitations and other constraints. It provides a constraint authoring system for adding other constraints to the scheduling process as needed. AMP is adaptable to assist with a variety of complex scheduling problems in manufacturing, transportation, business, architecture, and construction. AMP can benefit vehicle assembly plants, batch processing plants, semiconductor manufacturing, printing and textiles, surface and underground mining operations, and maintenance shops. For most of SHAI's commercial sales, the company obtains a service contract to customize AMP to a specific domain and then issues the customer a user license.

Source record↗

DOE OSTI2017

Complete carbon analysis of sulfur-containing mixtures using postcolumn reaction and flame ionization detection

Quantitative analysis of complex mixtures containing hundreds-to-thousands of organic compounds rich in heteroatoms, including oxygen, sulfur, and nitrogen, is a major challenge in the fuel, food, and chemical industries. In this work, a two-stage (oxidation and methanation) catalytic process in a 3-D–printed metal microreactor was evaluated for its capability to convert sulfur-containing organic compounds to methane. The microreactor was inserted into a gas chromatograph between the capillary column and flame ionization detector. Catalytic conversion of all sulfur-containing analytes to methane enabled carbon quantification without calibration, by the method identified as “quantitative carbon detection” or QCD. Quantification of tetrahydrothiophene, dimethyl sulfoxide, diethyl sulfide, and thiophene indicated complete conversion to methane at 450°C. Long-term performance of a commercial microreactor was evaluated for 2000 consecutive injections of sulfur-containing organic analytes. The sulfur processing capacity of the microreactor was identified experimentally, after which reduced conversion to methane was observed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Experimental Investigations on Solidification of 500-kg Steel Ingots with Laboratory Trials

The present work focuses on the solidification process of large steel ingots. Several complex solidification phenomena in large ingots were investigated by means of experimental hot modeling and cold modeling. In hot modeling, a 500 kg ingot solidified slowly in a specially insulated mold and this slow solidification process simulates the solidification of industrial scale ingots with a weight between 3 and 6 t. Temperature was measured by thermocouples during solidification and curves were plotted, and as-cast structure and macrosegregation of alloying elements were quantified. The A segregates were produced in the laboratory hot trials and quantitatively investigated. Meanwhile, water modeling (cold modeling) using NH{sub 4}Cl solution was conducted with different cooling/heating conditions. Macroscopic crystal growth phenomena, such as dendritic growth, sedimentation of crystals, and convective fluid flow, were directly observed and analyzed, and flow channels were also observed and compared with A segregates in the hot modeling.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Selecting Adsorbents to Separate Diverse Near-Azeotropic Chemicals

Industrial separations of near-azeotropic chemicals, species with very similar boiling points, are energy- and capital-intensive. Adsorption-based processes can energy-efficiently separate near-azeotropic mixtures provided suitable adsorbent materials can be found. Among the full diversity of industry-relevant molecules, millions of these mixtures exist, meaning that discovery of mixture-specific adsorbents by direct experiment is infeasible. We show that vast numbers of adsorbents and adsorbing molecules can be explored in a powerful way by coupling atomistic simulations with machine learning. This concept is demonstrated by describing the adsorption of ~54000 industry-relevant chemicals in an experimentally derived set of thousands of metal–organic framework materials. Here, our results identify thousands of near-azeotropic mixtures that can be efficiently separated using adsorption and open possibilities for creating adsorption processes for complex mixtures with many components.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Developing a remediation framework

When harmful contaminants are detected in soil, sediment, or groundwater (or suspected due to industrial activities), remediation efforts may be required to protect human health and the environment. This chapter will introduce and discuss the steps in the general site remediation process that are key when approaching any remediation strategy, regardless of the site complexity. While these steps are described in a linear fashion, in most cases, the approach is more fluid and iterative depending on the desired outcomes and success of each progressive clean-up effort along the way. This chapter will additionally articulate some key considerations which may be important to the overall remediation strategy depending on the particular needs and desired outcomes. From these more general discussions, the chapter will branch into a case-study of the remediation approach, or process steps, previously/currently/in the future taking place at the Hanford Site, as one example of a complex waste sites in the United States. As indicated earlier, while a remediation strategy can be more simply described by a progression of general process steps, it is far more likely to observe fluidity and strategy evolution over time from the first conceived strategy as remediation progress occurs. The chapter concludes with a brief discussion of how the strategy at the Hanford Site has evolved to provide a singular example of what this evolution might look like for other complex waste sites.

Muller, Katherine A.↗

DOE OSTI2021

Performance of Embedded Sensors in 3D Printed SiC

This report summarizes recent advances in embedding sensors in 3D printed silicon carbide (SiC) ceramic components under the Transformational Challenge Reactor (TCR) program. The additive manufacturing technologies developed under this program will enable fabrication of complex structures with embedded fuels and sensors. The sensors will be capable of characterizing fuel performance using spatially distributed measurements at the most strategic locations that would be otherwise inaccessible using conventional manufacturing techniques. While previous programmatic updates describe initial concepts for embedding sensors, materials selection, and initial characterization of the embedded sensors, the technology requires further demonstration, and quality-significant procedures must be established before the embedding technology is ready for adoption by industry. To this end, this report describes the most effective techniques that have been used to embed functional sensors in 3D printed components using a combination of binder-jet additive manufacturing and chemical vapor infiltration (CVI). A detailed procedure describes each step in the process and is available upon request. Molybdenum (Mo)-sheathed thermocouples have been successfully embedded in complex SiC components, and temperatures were monitored in situ during the embedding process. Post-embedding measurements showed no significant hysteresis, and characterization of the interface revealed qualitatively strong bonding around the entire perimeter of the sensor sheath. Distributed fiber-optic temperature sensors were able to briefly measure temperature profiles during CVI, but they ultimately failed prior to completion of the CVI run. The failure appears to be related to the fiber coating at temperatures close to 1,000°C. Future work will focus on irradiation testing of embedded thermocouples and other sheathed electrical sensors, as well as the identification of fiber-optic sensor coatings that can survive CVI.

42 ENGINEERING↗

NASA NTRS2019

GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-Cooled Combustion Chambers

GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices. This alloy is part of the family of NASA-developed GRCop, copper-chrome-niobium alloys. GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance. Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers. NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features. This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM. A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain. Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84. The GRCop-42 has completed process development and initial properties have been established. Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts. Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.

Gradl, Paul R.↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

NASA NTRS2023

The Coupling Between Tropical Meteorology, Aerosol Lifecycle, Convection, and Radiation, During the Clouds, Aerosol and Monsoon Processes Philippines Experiment (CAMP2Ex)

The NASA Cloud, Aerosol, and Monsoon Processes Philippines Experiment (CAMP2Ex) employed the NASA P-3, Stratton Park Engineering Company (SPEC) Learjet 35, and a host of satellites and surface sensors to characterize the coupling of aerosol processes, cloud physics, and atmospheric radiation within the Maritime Continent’s complex southwest monsoonal environment. Conducted in the late summer of 2019 from Luzon Philippines in conjunction with the Office of Naval Research Propagation of Intraseasonal Tropical OscillatioNs (PISTON) experiment with its R/VSally Ride stationed in the North Western Tropical Pacific, CAMP2Ex documented diverse biomass burning, industrial and natural aerosol populations and their interactions with small to congestus convection. The 2019 season exhibited El Nino and associated drought, high biomass burning emissions, and an early monsoon transition allowing for observation of pristine to massively polluted environments as they advected through intricate diurnal mesoscale and radiative environments into the monsoonal trough. CAMP2Ex’s preliminary results indicate 1) increasing aerosol loadings tend to invigorate congestus convection in height and increase liquid water paths; 2) lidar, polarimetry, and geostationary Advanced Himawari Imager remote sensing sensors have skill in quantifying diverse aerosol and cloud properties and their interaction; and 3) high resolution remote sensing technologies are able to greatly improve our ability to evaluate the radiation budget in complex cloud systems. Through the development of innovative informatics technologies, CAMP2Ex provides a benchmark dataset of an environment of extremes for the study of aerosol, cloud and radiation processes as well as a crucible for the design of future observing systems.

CAMP2Ex↗