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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Developing tools and process controls to manufacture energy-efficient powders for additive manufacturing feedstocks

Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075- T6) for studying mesh sensitivity, cutting forces, and chip morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Wind turbine blade material in the United States: Quantities, costs, and end-of-life options

Wind energy has experienced enormous growth in the past few decades; as a result, there are thousands of wind turbines around the world that will reach the end of their design lifetimes in the coming years. Much of the material in those turbines can be recycled using conventional processes, but the composite material that is the main component of the blades is more challenging to recycle. In the United States, turbine blades may be disposed of in landfills, adding a new solid waste stream to the material already being landfilled. This paper presents a spatially resolved estimate of the mass and volume of wind turbine blade waste in each state by 2050 and compares these amounts to estimates of the remaining landfill capacity by state. In this work, we estimate costs for each stage of the disposal process to indicate cost levels for alternatives. Assuming a 20-year turbine lifetime, the cumulative blade waste in 2050 is approximately 2.2 million tons. This value represents approximately 1% of remaining landfill capacity by volume, or 0.2% by mass. We also find that the current cost of disposing of blades in large segments or through grinding is relatively low in comparison to the overall life-cycle cost of energy. Based on these findings, landfill space constraints and disposal costs appear unlikely to motivate a change in waste handling strategies under current policy conditions. Instead, more profound shifts in recycling technologies, blade materials, or policy may be needed to move towards a circular economy for wind turbine blades.

17 WIND ENERGY↗
DOE OSTI2024

Toolpath generation for automated wind turbine blade finishing operations

Incorporating automation into wind turbine blade manufacturing is important for reducing costs to meet current offshore wind energy production goals in the United States. This work proposes a process for automating three operations in wind blade manufacturing: trimming to remove flashing left over after bonding two blade skins together, grinding to produce a desired leading-edge shape, and sanding to prepare the blade for bonding overlamination or adding paint to the surface. The majority of this work focuses on the toolpath generation. The algorithms were tested on a 5-m blade section, and the results were analyzed in terms of operation speed and accuracy. Finally, future work is discussed to improve the performance of the system.

17 WIND ENERGY↗
DOE OSTI2025

Developing tools and process controls to manufacture energy-efficient powders for additive manufacturing feedstocks: Computational analysis of metal powder manufacturing via machining

Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075-T6) for studying mesh sensitivity, cutting forces, and chip morphology.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Large-Eddy Simulation of a wind turbine using a Filtered Actuator Line Model

When dealing with multirotor devices such as quadcopters or wind farms, the cost of blade-resolved large-eddy simulation (LES) becomes prohibitive. Combining LES with a family of lower-fidelity models, called actuator line models (ALMs), has grown in popularity in the past decade. ALM replaces full blade resolution with an array of actuator points or lines parameterized by aerodynamic lift/drag polar plots along the blades. Body forces computed based on these actuator points are then projected onto the LES flow mesh, mimicking the effect of rotating blades on the flow. However, the optimal projection radius and the associated LES grid size is often too restrictive for multirotor simulations. Recently, a new tip-correction-based filtered ALM (F-ALM) was proposed by Martinez-Tossas and Meneveau (2019), which allows coarser-than-optimal grids by avoiding the associated overprediction of thrust. In this work, F-ALM is implemented into a high-order, in-house LES code to simulate National Renewable Energy Laboratory Phase VI wind turbine. It is then followed by a comparison between the baseline ALM and the newly implemented F-ALM in terms of instantaneous and time-averaged flow fields and blade loads, revealing the advantages of F-ALM in preventing the overprediction of power on coarse grids. Finally, this encourages accurate and affordable simulations of multirotor devices in the future.

17 WIND ENERGY↗
DOE OSTI2022

PNNL CRADA No. 488, Amendment 2 with Natel Energy, Inc.: The Center Sender

Under the Cooperative Research and Development Agreement (CRADA) No. 488, awarded to Natel Energy, Inc. (Natel) for third place in the Fish Protection Prize 2020 initiative, research was conducted on the Center Sender concept, a simple physical or combined physical and electrical device intended to guide fish to the safest path through a hydropower intake or water diversion. Applying this to a hydropower turbine, the Center Sender can be designed to divert fish to the center of the turbine, where blade velocities are slower and the risk of severe injuries due blade strike, pinching, and grinding are reduced.

13 HYDRO ENERGY↗
DOE OSTI2020

Isolation and characterization of lignocellulosic nanofibers from four kinds of organosolv-fractionated lignocellulosic materials

The objective of this research was to investigate the presence of residual lignin in cellulose fibers on the efficiency and energy consumption during nanofibers processing. Four kinds of lignin-containing cellulose nanofibers (LCNFs) from switchgrass, yellow poplar, hybrid poplar, and pine, respectively, were isolated via organosolv fractionation coupling mechanical grinding. Nanofibrils were observed after organosolv fractionation. The details of their morphological features, chemical structures, water retention value (WRV), and thermal degradation characteristics were revealed and compared. Mean diameters of nanofibers separated from switchgrass, yellow poplar, hybrid poplar, and pine were 27.9 nm, 25.4 nm, 24.6 nm, and 21.5 nm, respectively. The presence of lignin for the four types of LCNFs led to a decrease in energy consumption and an increase in WRV, among which pine nanofibers show the best with an average energy consumption of 0.511 kWh/kg and a WRV of 537%. It was also demonstrated that increasing lignin content for LCNFs could contribute to the sample’s thermal stability. In conclusion, exact benefits of residual lignin for nanofiber will facilitate its preparation process and extend its application.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Tungsten solution kinetics and amorphization of nickel in mechanically alloyed Ni-W alloys

The kinetics of solution of W, and the subsequent amorphization of Ni, in mechanically alloyed Ni-W alloys has been investigated. As W is a highly abrasive material in the energy intensive devices used for mechanical alloying, we studied the above reactions in different mills. One used hardened steel balls as the grinding media, and the other Al2O3. Abrasion is common to both mills, but Fe wear debris from the hardened steel enters into solution in the Ni rich phases whereas Al2O3 debris is present as small dispersoids. The kinetics of W solution and those of subsequent amorphization do not appear strongly affected by the Fe in solution or the Al2O3 dispersoid. Tungsten dissolves in crystalline Ni in amounts in excess of the equilibrium solubility during alloying. Amorphization of the Ni phase occurs if the W content in this phase exceeds ca. 28 at. pct.

Aning, A. O.↗
NASA NTRS1998

Proposed Wind Turbine Aeroelasticity Studies Using Helicopter Systems Analysis

Advanced systems for the analysis of rotary wing aeroelastic structures (helicopters) are being developed at NASA Ames by the Rotorcraft Aeromechanics Branch, ARA. The research has recently been extended to the study of wind turbines, used for electric power generation Wind turbines play an important role in Europe, Japan & many other countries because they are non polluting & use a renewable source of energy. European countries such as Holland, Norway & France have been the world leaders in the design & manufacture of wind turbines due to their historical experience of several centuries, in building complex wind mill structures, which were used in water pumping, grain grinding & for lumbering. Fossil fuel cost in Japan & in Europe is two to three times higher than in the USA due to very high import taxes. High fuel cost combined with substantial governmental subsidies, allow wind generated power to be competitive with the more traditional sources of power generation. In the USA, the use of wind energy has been limited mainly because power production from wind is twice as expensive as from other traditional sources. Studies conducted at the National Renewable Energy Laboratories (NREL) indicate that the main cost in the production of wind turbines is due to the materials & the labor intensive processes used in the construction of turbine structures. Thus, for the US to assume world leadership in wind power generation, new lightweight & consequently very flexible wind turbines, that could be economically mass produced, would have to be developed [4,5]. This effort, if successful, would result in great benefit to the US & the developing nations that suffer from overpopulation & a very high cost of energy.

Ladkany, Samaan G.↗
NASA NTRS2017

Structural Design Parameters for Germanium

The fracture toughness and slow crack growth parameters of germanium supplied as single crystal beams and coarse grain disks were measured. Although germanium is anisotropic (A* 1.7), it is not as anisotropic as SiC, NiAl, or Cu. Thus the fracture toughness was similar on the 100, 110, and 111 planes, however, measurements associated with randomly oriented grinding cracks were 6 to 30 higher. Crack extension in ring loaded disks occurred on the 111 planes due to both the lower fracture energy and the higher stresses on stiff 111 planes. Germanium exhibits a Weibull scale effect, but does not exhibit significant slow crack growth in distilled water. (n 100), implying that design for quasi static loading can be performed with scaled strength statistics. Practical values for engineering design are a fracture toughness of 0.69 0.02 MPam (megapascals per square root meter) and a Weibull modulus of m 6 2. For well ground and reasonable handled coupons, average fracture strength should be greater than 40 megapascals. Aggregate, polycrystalline elastic constants are Epoly 131 gigapascals, vpoly 0.22.

fracture toughness↗
DOE OSTI2023

Grinding and Pelleting Characteristics of Municipal Solid Waste Fractions

The efficient utilization of low-cost carbon feedstocks, such as municipal solid waste (MSW), in biorefineries has become increasingly important for reducing GHG emissions and meeting the growing demand for renewable energy sources. However, MSW as a feedstock presents several challenges, including high moisture content, compositional variability, particle size and shape, density, and ash content. To address these challenges, the potential of mechanical dewatering and high-moisture pelleting processes for densifying MSW fractions, such as paper, cardboard, thin plastic, and thick plastic, into low-cost carbon feedstocks with improved handling and conversion properties were investigated. The effect of these preprocessing technologies on the critical quality attributes (CQAs) of the resulting pellets, including bulk density, durability, and size uniformity, were evaluated. The results showed that with these preprocessing technologies, the paper and cardboard fractions could be pelleted at moisture contents over 40% (w.b.) while achieving >99% durability and >300 kg/m3, while the high moisture plastic fractions were not suitable for pelleting. The thick plastic fraction processed in a screw press was shown to remove up to 30% of the moisture content in a single pass. These findings suggest that these mechanical preprocessing technologies can improve the physical properties of low-cost municipal solid waste fractions for biofuels production.

09 BIOMASS FUELS↗
NASA NTRS2001

Fabricating High Resolution Mirrors for Hand X-Ray Astronomy

We describe the fabrication process for producing high-resolution conical mirrors for hard x-ray astronomy. When flown aboard stratospheric balloons, these high-resolution reflective mirrors focus hard x-rays (10-70 keV) emitted from cosmic sources such as supernovae, neutron stars, and quasars onto imaging focal plane detectors. Focused hard x-ray images allow scientists to determine the elemental compositions, temperatures, magnetic fields, velocities, and gravitational fields of these celestial bodies. The fabrication process involves generating super-polished mandrels, mandrel metrology, mirror shell nickel electroforming, and mirror testing. Each mandrel is a cylinder consisting of two conical segments; each segment is approximately 305-mm long. Through precision grinding these mandrels before super polishing, we have achieved 30 arc seconds, half power diameter replicated mirrors. During a May 2001 high atmosphere balloon flight, these mirrors focused high energy x-rays from three different celestial sources. However, we seek to improve the angular resolutions of future mirror shells by a factor of two. To achieve this goal, we have begun single point diamond turning the mandrels before super polishing. This has allowed greater precision tolerances on mandrel surface roughness and axial figure errors before super polishing. Surface roughnesses before polishing have been reduced from approximately 60 nm to approximately 15 nm. The peak to valley axial figure profile errors have been reduced from approximately 1.0 micrometers to approximately 0.4 micrometers. We are currently in Phase 2 of the HERO (high energy replicated optics) program which entails the production of sixteen 6-m-focal-length mirror modules, each containing a nested array of 15 mirror shells of diameters ranging from 50-mm to 94-mm. This flight is slated for the fall of 2003.

Speegle, Chet O.↗
DOE OSTI2022

Air classification of forest residue for tissue and ash separation efficiency

The goal of this Case Study was to evaluate the performance of air classification of logging residues toward meeting conversion CMAs for carbon and ash contents, as compared to the static status quo Base Case system in which the residues are first dried and then ground in a hammer mill with a 6 mm screen and fines < 1.18 mm are removed. Also considered were moisture and ash impacts on throughput and Overall Operating Effectiveness (OOE), as well as delivered feedstock cost and minimum fuel selling price (MFSP). Laboratory data on the impacts of fan speed and moisture content on the separation efficiency of soil ash, needles and bark from white wood were received from FCIC Subtask 5.2. Average throughput and energy consumption data were obtained from the Bioenergy Feedstock National User Facility (BFNUF) for the same air classifier. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the Base Case status quo system utilizes drying prior to grinding, we modeled the Case Study with drying prior to air classification and subsequent grinding of the separated white wood to isolate the individual quality and cost impacts of air classification relative to the Base Case system. Key takeaways from this Case Study are that air classification improves the quality of the final material, but increases the production cost, especially when lights are disposed; this becomes a tradeoff between increased conversion yield and the extra cost. Removing material should be done as early in the process as possible. Each operation that occurs prior to removing the material increases the cost of the disposed material and leads to wasted energy expenditures. As processes are included or modified, the impact on monetary and energy cost should be included in the decision process. Identifying alternative uses and the associated value for material that is separated from the feedstock stream will have a significant impact on the delivered cost of the material. Although there was an increase in production cost by adding air classification, there was a resulting benefit to the MFSP when meeting or exceeding all of the conversion CMAs; this was an important finding that should be explored further with FCIC Subtask 8.3 and potentially FCIC Task 6.

09 BIOMASS FUELS↗
DOE OSTI2023

Effects of magnetic field annealing on the hard magnetic properties of milled Nd-Fe-B powders

In this study, we report the effect of magnetic field annealing (MA) in relieving the stress induced during the milling of Nd-Fe-B sintered magnets. The effect of MA processing parameters and particle size on the magnetic properties were investigated. Based on the results, magnetic field annealing is more effective in improving the magnetic properties of larger size particles, compared to finer particles. Our computational study on the role of particle surface defects in bi-modal particle distribution agrees with results obtained experimentally. In conclusion, magnetic field annealed powder has been successfully used to develop 4.6 g.cm -3 density bonded magnets with 75 vol% of magnetic powder and polyamide 12 (nylon 12) polymer binder resulting in 11.3 MGOe energy product.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Economic viability of photovoltaic power for development assistance applications

This paper briefly discusses the development assistance market and examines a number of specific photovoltaic (PV) development assistance field tests, including water pumping/grain grinding (Tangaye, Upper Volta), vaccine refrigerators slated for deployment in 24 countries, rural medical centers to be installed in Ecuador, Guyana, Kenya and Zimbabwe, and remote earth stations to be deployed in the near future. A comparison of levelized energy cost for diesel generators and PV systems covering a range of annual energy consumptions is also included. The analysis does not consider potential societal, environmental or political benefits associated with PV power. PV systems are shown to be competitive with diesel generators, based on life cycle cost considerations, assuming a system price of $20/W(peak), for applications having an annual energy demand of up to 6000 kilowatt-hours per year.

Bifano, W. J.↗
DOE OSTI2020

Solvent‐Free Self‐Assembly for Scalable Preparation of Highly Crystalline Mesoporous Metal Oxides

Abstract Mesoporous metal oxides (MMOs) have been demonstrated great potential in various applications. Up to now, the direct synthesis of MMOs is still limited to the solvent induced inorganic‐organic self‐assembly process. Here, we develop a facile, general, and high throughput solvent‐free self‐assembly strategy to synthesize a series of MMOs including single‐component MMOs and multi‐component MMOs (e.g., doped MMOs, composite MMOs, and polymetallic oxide) with high crystallinity and remarkable porous properties by grinding and heating raw materials. Compared with the traditional solution self‐assembly process, the avoidance of solvents in this method not only greatly increases the yield of target products and synthesis efficiency, but also reduces the environmental pollution and the consumption of cost and energy. We believe the presented approach will pave a new avenue for scalable production of advanced mesoporous materials for various applications.

Xiong, Hailong↗
DOE OSTI2020

Solvent-Free Self-Assembly for Scalable Preparation of Highly Crystalline Mesoporous Metal Oxides

Mesoporous metal oxides (MMOs) have been demonstrated great potential in various applications. Up to now, the direct synthesis of MMOs is still limited to the solvent induced inorganic-organic self-assembly process. In this work, we develop a facile, general, and high throughput solvent-free self-assembly strategy to synthesize a series of MMOs including single-component MMOs and multi-component MMOs (e.g., doped MMOs, composite MMOs, and polymetallic oxide) with high crystallinity and remarkable porous properties by grinding and heating raw materials. Compared with the traditional solution self-assembly process, the avoidance of solvents in this method not only greatly increases the yield of target products and synthesis efficiency, but also reduces the environmental pollution and the consumption of cost and energy. We believe the presented approach will pave a new avenue for scalable production of advanced mesoporous materials for various applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2003

An Examination of Issues Related to a Europa Subsurface Component for the JIMO Mission

The Galileo Europa data set served to revolutionize our view of Europa. In particular the strong evidence of a large, cold, salty Ocean beneath 5-30 km of ice has profoundly altered the significance of Europa in our thinking, especially of context of habitability in the solar system. While much remains to be learned from spacecraft observations of several sorts, there are significant questions answerable only by in-situ techniques; these relate to the formation of Europa, the nature of its ocean, and the prospects for life in its ocean, sediments, and ice. We feel that wide-ranging discussion of an in-situ subsurface mission to Europa, as part of JIMO, should proceed. The science objective of the mission is to characterize the icy shell of Europa to resolve its provenance, estimate the composition of brine of the Europa ocean, and search for evidence of Earth-like life. Probably anyone would agree that an in-situ mission to Europa would be of great value, but he or she would also immediately take the position that such a mission is utterly impractical. We take the position here of defining the least complex mission that can nonetheless justify its cost and to argue that such a mission is realistic enough that it should be seriously considered. Our mission thinking has been: 1) Soft landing. A soft lander is required on a site sufficiently flat to offer a stable platform; no further site selectivity is required. 2) Subsurface exploration. The Europa subsurface must be examined. Surficial processes on Europa arguably have exposed the upper 200 m of shell to chemical effects from the Jovian radiation belts as well as cometary infall, etc; to examine native ice we must descend below that point to, for discussion, 300 m. At that depth we argue that the ice is characteristic of ice at depth and possibly is effectively sea ice. 3) Science data. A few simple measurements at various depths and at 300 m constitute a scientifically successful mission. Measurements would include analysis of meltwater for a few inorganic ions and amino acids and an optical examination of the borehole wall. 4) Communication. Transmission of data to an orbiter is essential, but we will constrain the landed mission to a daily communication over a few days. 5) Subsurface access. Drilling to 300 m is a significant challenge; it can be addressed by several means: Thermal Probe (Cryobot) which permits water to refreeze above the vehicle. This is our tentative choice with plutonium as the fuel to generate thermal energy for drilling and electrical power for operations. Open Hole Drill, a thermal system in which the meltwater is removed for greater thermal efficiency. Meltwater removal on Europa is both a complexity and a risk, but analysis is improved. Mechanical Drilling in which cutting or grinding generates ice chips which are removed. This is too complex at Europa temperatures. The measurement objectives for the mission will be: Obj. 1: Determine the concentration of simple inorganic salts in the Europa Ice Shell and, by extrapolation, of the ocean. These data will also validate spaceborne sensors. Obj. 2: Determine the nature and abundance of amino acids in the ice such that cometary infall material in the upper ice can be compared to material at depth. Obj. 3: Optically examine the ice to resolve inclusion structure, particulate content, and stratification. Access to 300 m depth is a significant if not audacious plan; we are aware that this has not been done on any planetary body. Our approach is the use of a plutonium heat source; to overcome Europa's surface temperature and to melt ice a significant amount of plutonium is needed, and significant shielding and other protective steps will be required. The quantity of plutonium is a key concern. The mission will require subsurface collection and processing of samples for in situ analysis, calling for a miniature, high pressure micro-sampling system designed to meet needs of instruments that require low presses for operation. The inlet system itself collects a micro-sample in the external high pressure environment, then transfers it into a protected low pressure environment for analysis.

Carsey, F. D.↗