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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Surface Tagging with Photoluminescent Particles (Summary Report for FY22)

This report describes the results of initial welding trials for the purpose of implanting photoluminescent taggants in the form of metal-based oxides on the surface of a base material for future detection. The goal of this work was to explore the feasibility of using photoluminescent particles as surface tags for nuclear fuels and related materials (e.g., cladding). These tags could be used to store information about material provenance while being difficult to observe with the naked eye. This work is one of many related projects focused on nuclear fuel tagging, at the surface and bulk level, and is part of a multi-site Venture project. This tactic should not be viewed as a sole solution to tagging fuel, but rather a potential manufacturing strategy that may be implemented alongside other tagging strategies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Cold Spray Additive Manufacturing For New Pipeline Fabrication In Live, Natural Gas Distribution Mains

ULC Technologies (ULC) and the Penn State University Applied Research Lab (PSU ARL) developed a process and approach for rehabilitating live, natural gas distribution pipelines using Cold Spray Additive Manufacturing (CSAM). Robotic inline fabrication of a new pipe will be performed inside a natural gas main without disrupting customers. The material studied was blended with stainless steel which offers corrosion resistance, high strength and compatibility with hydrogen to enable a robust pipeline system that is future proofed. Stainless steel coatings sprayed and tested in the lab showed excellent strength, ductility, and porosity values. ULC initially sought to use methane as the process gas for compatibility with the host pipe, but after evaluating the field and lab challenges, nitrogen was deemed to be more suitable. Early robotic concepts have been developed that indicate technical feasibility. While the technology development originally targeted natural gas distribution mains, market research showed a broader need. Spot repairs performed in natural gas transmission mains may be a more economical approach for reinforcing distribution and transmission mains compared with full pipe-in-pipe rehabilitation. Additive manufacturing offers custom programming, as well as high accuracy and precision. This means custom contours can be manufactured in situ, offering flexibility in the repair solution, such as fabricating internal full circumferential sleeves. The value of the repair can be high at difficult-to-reach locations and in pipes that need reinforcement before the injection of methane-hydrogen blends.

03 NATURAL GAS↗
DOE OSTI2026

Low-Temperature Plasma-Based Metrology of Lithium-Ion Battery Electrode Materials (CRADA Final Report)

As part of the Cyclotron Road program, SirenOpt Inc. evaluated its low-temperature plasma-based metrology sensor prototype for measuring multiple critical properties of lithium-ion battery electrode materials in parallel and in real-time. Cost-effective, minimal-waste manufacturing of high-performance battery electrode materials will be vital for achieving society’s net-zero carbon emission goals. Because existing electrode metrology sensors cannot operate within most sections of manufacturing lines, manufacturers often complete hundreds of processing steps before they can test their products and detect problems. When manufacturers perform these offline tests, they typically only test a small portion of the manufactured products. Current electrode manufacturing thus often yields many low-quality products, or off-spec products that must be thrown away all together. For example, at least 6% of the total lithium-ion battery manufacturing cost (i.e., over $250 million/year for the average gigafactory) is devoted to processing defective electrodes that are not scrapped until performance tests are failed during late-stage quality control checks. Electrode variability also leads manufacturers to build extra cells into battery packs to reduce the risk of poor performance. For example, many electric vehicle (EV) manufacturers include up to 10% more cells than needed, which substantially increases the cost and weight of the final EV product. The SirenOpt sensor can potentially enable early detection of poorly manufactured electrodes and allow them to be removed earlier from manufacturing lines, which can save battery manufacturers (hundreds of) millions of dollars per year. The sensor can further be used to improve product quality by accelerating R&D and process optimization, improving quality control, and enabling real-time process control. Overall, a real-time, in-situ metrology strategy can create unprecedented opportunities for implementation of smart manufacturing practices and advanced quality and process control solutions to realize higher battery electrode throughput and performance.

25 ENERGY STORAGE↗
NASA NTRS1978

Center punched solar cell module development effort

The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.

Ross, R. E.↗
NASA NTRS1978

New works in space

Goods and services that may be furnished by the Space Shuttle are described. A single multibeam antenna array capable of supplying satellite communication for 256 U.S. cities, a disaster warning network, and a TV link to remote areas is discussed. Attention is also given to such materials processing programs as crystal growth (for example, production of mercuric iodide crystals for gamma-ray detectors), eutectic growth of solid-solution crystals such as mercury-cadmium-telluride, manufacture of uniform latex spheres for medical applications, and development of small glass spheres for fusion power applications. In addition to the Space Telescope, a meter-class telescope on the Shuttle and a wide-field survey instrument are under study.

Kingsbury, J. E.↗
NASA NTRS1979

Process for the manufacture of carbon or graphite fibers

Carbon or graphite fibers are manufactured by heating polyacrylonitrile fiber materials in various solutions and gases. They are characterized in that the materials are heated to temperatures from 150 to 300 C in a solution containing one or more acids from the group of carbonic acids, sulfonic acids, and/or phenols. The original molecular orientation of the fibers is preserved by the cyclization that occurs before interlacing, which gives very strong and stiff carbon or graphite fibers without additional high temperature stretching treatments.

Overhoff, D.↗
NASA NTRS2000

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction

Four roller profiles used in cylindrical roller bearing design and manufacture were analyzed using both a closed form solution and finite element analysis (FEA) for stress and life. The roller profiles analyzed were flat, tapered end, aerospace, and fully crowned loaded against a flat raceway. Four rolling-element bearing life models were chosen for this analysis and compared. These were those of Weibull, Lundberg and Palmgren, Ioannides and Harris, and Zaretsky. The flat roller profile without edge loading has the longest predicted life. However, edge loading can reduce life by as much as 98 percent. The end tapered profile produced the highest lives but not significantly different than the aerospace profile. The fully crowned profile produces the lowest lives. The resultant predicted life at each stress condition not only depends on the life equation used but also on the Weibull slope assumed. For Weibull slopes of 1.5 and 2, both Lundberg-Palmgren and Iaonnides-Harris equations predict lower lives than the ANSI/ABMAJISO standards. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field.

Poplawski, Joseph V.↗
NASA NTRS1999

Portable Inspection

The portable SpectroReflectometer, an instrument developed by AZ Technology, Inc. in partnership with NASA's Kennedy Space Center is now being manufactured and sold as a cost-effective solution to the development of scientific space flight hardware. This technology originated with the efforts to determine the degradation mechanisms of the space environment on space craft materials. AZ Technology's mission is to provide high quality products and services in electro-mechanical-optical design and hardware integration, advanced thermal and optical coatings and materials, and in the development of custom hardware systems for scientific measurements.

Source record↗
NASA NTRS2002

An Analysis of Computer Aided Design (CAD) Packages Used at MSFC for the Recent Initiative to Integrate Engineering Activities

This paper analyzes the use of Computer Aided Design (CAD) packages at NASA's Marshall Space Flight Center (MSFC). It examines the effectiveness of recent efforts to standardize CAD practices across MSFC engineering activities. An assessment of the roles played by management, designers, analysts, and manufacturers in this initiative will be explored. Finally, solutions are presented for better integration of CAD across MSFC in the future.

Smith, Leigh M.↗
DOE OSTI2023

Lithium metal negative electrode and method of manufacturing the same

A negative electrode for an electrochemical cell of a secondary lithium metal battery is manufactured by a method in which a precursor solution is applied to a major surface of a lithium metal substrate to form a precursor coating thereon. The precursor solution includes an organophosphate, a nonpolar organic solvent, and a lithium-containing inorganic ionic compound dissolved therein. At least a portion of the nonpolar organic solvent is removed from the precursor coating to form a protective interfacial layer on the major surface of the lithium metal substrate. The protective interfacial layer exhibits a composite structure including a carbon-based matrix component and a lithium-containing dispersed component. The lithium-containing dispersed component is embedded in the carbon-based matrix component and includes a plurality of lithium-containing inorganic ionic compounds, e.g., lithium phosphate (Li3PO4) and lithium nitrate (LiNO3).

Xiao, Xingcheng↗
NASA NTRS2015

Thermal Protection System Application to Composite Cryotank Technology Demonstrator

The EM41 Thermal Protection System (TPS) team contributed to the success of the Composite Cryotank Technology Demonstrator (CCTD) manufacturing by developing and implementing a low-cost solution to apply cryoinsulation foam on the exterior surface of the tank in the NASA Marshall Space Flight Center (MSFC) TPS Development Facility, Bldg. 4765. The TPS team used techniques developed for the smallscale composite cryotank to apply Stepanfoam S-180 polyurethane foam to the 5.5-meter CCTD using a manual spray process. Manual spray foam technicians utilized lifts and scaffolding to access the barrel and dome sections of the large-scale tank in the horizontal orientation. During manufacturing, the tank was then oriented vertically, allowing access to the final barrel section for manual spray foam application. The CCTD was the largest application of manual spray foam performed to date with the S-180 polyurethane foam and required the TPS team to employ best practices for process controls on the development article.

Protz, Alison↗
DOE OSTI2024

3D Integrated Sensing Solutions

We will present the proposed research project to develop 3D-integrated sensors using advanced manufacturing capability for novel sensors, heterogeneously integrated with energy efficient readout circuits. The lack of precision timing in particle tracking detectors and the absence of low power, high throughput communications solutions to read them out limits progress in multiple fields of fundamental science. The aim of the project is to develop technology to enable large-scale particle detectors with 3D-integrated ASIC designs to simultaneously achieve 10 μm position resolution and 10 ps precision timing, with low-power consumption and high throughput rates. This research program leverages the unique combination of facilities and cross-disciplinary expertise of scientists and engineers at SLAC, FNAL, and LLNL and industrial partners.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Additively Manufactured Solid-State Luminaire

This project addresses several key barriers to wide-spread adoption of additive manufacturing (AM) technology as applied to solid state lighting luminaires. The solution will utilize cutting edge AM approaches for integrating structure with thermal management solutions, electronic functionality, and optics. The research team (Eaton, Lighting Research Center (LRC) at Rensselaer Polytechnic Institute, Xerox Research Centre of Canada (XRCC)) utilize their AM and lighting expertise to investigate breakthrough manufacturing approaches that will significantly reduce cost, eliminate manufacturing process waste, and improve luminaire efficacy. The team has identified critical areas of research and proposed novel technical approaches to achieve these goals. Key areas of focus in Budget Period 1 (BP1) of the project quantified the impact of applying AM methodologies to the main, discrete subsystem components (Heat Sink, Housing, Optics, Electronics). Budget Period 2 (BP2) research explored similar impact on a fully integrated, AM modular luminaire concept. Final Achievement of the Target Metrics for the project are as follows: Material Reduction: achieved > 57.45% (target is 50%) Manufacturing Process: achieved > 51% reduction (target is 50%) Application Efficacy: achieved 126 lm/W (target is 130 lm/W) First Cost vs Baseline: demonstrated 49% improvement in project timing, 59% improvement in man hour savings and 89% worse BOM costs (due to deficiencies in current “state of the art” equipment). The BOM costs improve to 53% savings if state of the art processes and equipment could have been used.

3D Printing↗
DOE OSTI2023

Solution Processed Schottky Diodes Enabled by Silicon Carbide Nanowires for Harsh Environment Applications

Silicon carbide nanowires (SiC NWs) exhibit promising features to allow solution-processable electronics to be deployed in harsh environments. By utilizing a nanoscale form of SiC, we were able to disperse the material into liquid solvents, while maintaining the resilience of bulk SiC. Here, this letter reports the fabrication of SiC NW Schottky diodes. Each diode consisted of just one nanowire with an approximate diameter of 160 nm. In addition to analyzing the diode performance, the effects of elevated temperatures and proton irradiation on the current–voltage characteristics of SiC NW Schottky diodes were also examined. The device could maintain similar values for ideality factor, barrier height, and effective Richardson constant upon proton irradiation with a fluence of 10 16 ion/cm 2 at 873 K. As a result, these metrics have clearly demonstrated the high-temperature tolerance and irradiation resistance of SiC NWs, ultimately indicating that they may provide utility in allowing solution-processable electronics in harsh environments.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS2001

Development of a fully integrated analysis system for ions based on ion-selective optodes and centrifugal microfluidics

A fully integrated, miniaturized analysis system for ions based on a centrifugal microfluidics platform and ion-selective optode membranes is described. The microfluidic architecture is composed of channels, five solution reservoirs, a measuring chamber, and a waste reservoir manufactured onto a disk-shaped substrate of poly(methyl methacrylate). Ion-selective optode membranes, composed of plasticized poly(vinyl chloride) impregnated with an ionophore, a proton chromoionophore, and a lipophilic anionic additive, were cast, with a spin-on device, onto a support layer and then immobilized on the disk. Fluid propulsion is achieved by the centrifugal force that results from spinning the disk, while a system of valves is built onto the disk to control flow. These valves operate based on fluid properties and fluid/substrate interactions and are controlled by the angular frequency of rotation. With this system, we have been able to deliver calibrant solutions, washing buffers, or "test" solutions to the measuring chamber where the optode membrane is located. An analysis system based on a potassium-selective optode has been characterized. Results indicate that optodes immobilized on the platform demonstrate theoretical responses in an absorbance mode of measurement. Samples of unknown concentration can be quantified to within 3% error by fitting the response function for a given optode membrane using an acid (for measuring the signal for a fully protonated chromoionophore), a base (for fully deprotonated chromoionophore), and two standard solutions. Further, the ability to measure ion concentrations by employing one standard solution in conjunction with acid and base and with two standards alone were studied to delineate whether the current architecture could be simplified. Finally, the efficacy of incorporating washing steps into the calibration protocol was investigated.

NASA Discipline Life Sciences Technologies↗
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Subsampling of Parametric Models with Bifidelity Boosting

Least squares regression is a ubiquitous tool for building emulators (a.k.a. surrogate models) of problems across science and engineering for purposes such as design space exploration and uncertainty quantification. When the regression data are generated using an experimental design process (e.g., a quadrature grid) involving computationally expensive models, or when the data size is large, sketching techniques have shown promise at reducing the cost of the construction of the regression model while ensuring accuracy comparable to that of the full data. However, random sketching strategies, such as those based on leverage scores, lead to regression errors that are random and may exhibit large variability. To mitigate this issue, we present a novel boosting approach that leverages cheaper, lower-fidelity data of the problem at hand to identify the best sketch among a set of candidate sketches. This in turn specifies the sketch of the intended high-fidelity model and the associated data. We provide theoretical analyses of this bifidelity boosting (BFB) approach and discuss the conditions the low- and high-fidelity data must satisfy for a successful boosting. In doing so, we derive a bound on the residual norm of the BFB sketched solution relating it to its ideal, but computationally expensive, high-fidelity boosted counterpart. Finally, empirical results on both manufactured and PDE data corroborate the theoretical analyses and illustrate the efficacy of the BFB solution in reducing the regression error, as compared to the nonboosted solution.

97 MATHEMATICS AND COMPUTING↗