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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 OSTI2022

Application of Box-Behnken design in optimizing product properties of supercritical methanol co -liquefaction of rice straw and linear low-density polyethylene

We report co-processing of plastic and biomass wastes to produce high-quality fuel has been attracting considerable interest in energy recovery. This work employed Box-Behnken Design (BBD) to optimize yield and properties of oil from supercritical methanol (scMeOH) co-liquefaction of rice straw (RS) and linear low-density polyethylene (LLDPE). Three independent variables of reaction temperature (270, 300, and 330°C), holding time (60, 90, and 120 mins), and RS/LLDPE mass ratio (0.15, 0.50, and 0.85) were selected for experiments. A maximum oil yield of 34.17 wt% was achieved at 303°C, 96 mins, and RS/LLDPE ratio of 0.59 according to BBD. Temperature and RS/LLDPE ratio dominated the oil yield and synergistic effects during co-liquefaction, whereas time was an insignificant factor. Optimum oil from co-liquefaction contained substantial hydrocarbons content of 32.91% compared to that from single RS-derived oil of 7.77%. Solid product obtained at the optimum condition could be used as solid fuel, due to its relatively high HHV of 43.08 MJ/kg compared to the other solid fuels (13.90–32.14 MJ/kg). This work provides a deep understanding of the co-processing of solid biomass and plastic wastes.

09 BIOMASS FUELS↗
DOE OSTI2023

Optimized thermodynamic properties of REE aqueous species (REE 3+ and REEOH 2+ ) and experimental database for modeling the solubility of REE phosphate minerals (monazite, xenotime, and rhabdophane) from 25 to 300 °C

Rare earth elements (REE) are critical elements found in monazite, xenotime, and hydrated REE phosphates which typically form in hydrothermal mineral deposits. Accurate predictions of the solubility of these REE phosphates and the speciation of REE in aqueous fluids are both key to understanding the controls on the transport, fractionation, and deposition of REE in natural systems. Previous monazite and xenotime solubility experiments indicate the presence of large discrepancies between experimentally derived solubility constants versus calculated solubilities by combining different data sources for the thermodynamic properties of minerals and aqueous species at hydrothermal conditions. In this study, these discrepancies were resolved by using the program GEMSFITS to optimize the standard partial molal Gibbs energy of formation (Δ f G° 298 ) of REE aqueous species (REE 3+ and REE hydroxyl complexes) at 298.15 K and 1 bar while keeping the thermodynamic properties fixed for the REE phosphates. A comprehensive experimental database was compiled using solubility data available between 25 and 300 °C. The latter permits conducting thermodynamic parameter optimization of Δ f G° 298 for REE aqueous species. Optimal matching of the rhabdophane solubility data between 25 and 100 °C requires modifying the Δ f G° 298 values of REE 3+ by 1–6 kJ/mol, whereas matching of the monazite solubility data between 100 and 300 °C requires modifying the Δ f G° 298 values of both REE 3+ and REEOH 2+ by ~15–31 kJ/mol and ~2–10 kJ/mol, respectively. For xenotime, adjustments of Δ f G° 298 values by 1–26 kJ/mol are only necessary for the REE 3+ species. The optimizations indicate that the solubility of monazite in acidic solutions is controlled by the light (L)REE 3+ species at <150 °C and the LREEOH 2+ species at >150 °C, whereas the solubility of xenotime is controlled by the heavy (H)REE 3+ species between 25 and 300 °C. Based on the optimization results, we conclude that the revised Helgeson-Kirkham-Flowers equation of state does not reliably predict the thermodynamic properties of REE 3+ , REEOH 2+ , and likely other REE hydroxyl species at hydrothermal conditions. We therefore provide an experimental database (ThermoExp_REE) as a basic framework for future updates, extensions with other ligands, and optimizations as new experimental REE data become available. As a result, the optimized thermodynamic properties of aqueous species and minerals are available open access to accurately predict the solubility of REE phosphates in fluid-rock systems.

58 GEOSCIENCES↗
DOE OSTI2026

Low Activity Waste Glass Optimization with Property Models from Machine Learning, Part 2: Experimental Validation and Active Learning

The United States Department of Energy is responsible for managing legacy nuclear waste stored in underground tanks at the Hanford Site. To treat the waste, it is planned as the current baseline to separately vitrify low-activity waste (LAW) and high-level waste fractions. Previously, machine learning (ML) based glass property models (e.g., chemical durability, viscosity, electrical conductivity and SO3 solubility) were developed with prediction uncertainties. A waste glass optimization approach was then established to enable the capability of using these ML models in LAW glass formulation. In this study, the previous ML models were first experimentally validated, and the results were incorporated back into the database to update the ML models. The updated models and formulations showed increased waste loading while reducing the failure rate, demonstrating improved predictive accuracy, reduced uncertainties, and the effectiveness of active learning in guiding high-dimensional, nonlinear LAW glass design. This represents the first experimental validation of ML based LAW glass formulation, with practical benefits such as higher waste loading, shorter mission duration, and lower operational risk.

Lu, Xiaonan (ORCID:0000000179708148)↗
NASA NTRS1990

Stochastic ordering properties and optimal routing control for a class of finite capacity queueing systems

The problem of routing jobs to parallel queues with identical exponential servers and unequal finite buffer capacities is considered. Stochastic ordering and weak majorization properties on critical performance measures are established by means of event-driven inductions. In particular, it is shown that the intuitive 'join the shortest non-full queue' (SNQ) policy is optimal with respect to an overall function that accounts for holding and blocking costs. Moreover, the buffer allocation problem is solved by proving the intuitive result that, for a fixed total buffer capacity, the optimal allocation scheme is the one in which the difference between the maximum and minimum queue capacities is minimized, i.e., becomes either 0 or 1.

Towsley, Don↗
NASA NTRS2001

Skeletal adaptation to external loads optimizes mechanical properties: fact or fiction

The skeleton adapts to a changing mechanical environment but the widely held concept that bone cells are programmed to respond to local mechanical loads to produce an optimal mechanical structure is not consistent with the high frequency of bone fractures. Instead, the author suggests that other important functions of bone compete with mechanical adaptation to determine structure. As a consequence of competing demands, bone architecture never achieves an optimal mechanical structure. c2001 Lippincott Williams & Wilkins, Inc.

Review, Tutorial↗
DOE OSTI2023

Glass formulation and composition optimization with property models: A review

Abstract Glass is a versatile material with a remarkable history and many practical applications. It plays a critical role in our everyday lives, the advancement of science, and the development of many technologies. The Edisonian type trial‐and‐error method was commonly used for conventional design of glass compositions, which was time‐consuming and costly. With the urgent need to develop new glass compositions for technology applications rapidly, it has become necessary to develop precise property models with predictive powers using large databases and efficient formulation approaches. This paper reviews the design of glass compositions using these analytical and numerical models of composition–structure–property relations of glasses, some based on large databases and machine learning approaches. Aspects of data collection, model fitting, feature extraction, model evaluation, and uncertainty quantification will be covered. Furthermore, advances in the glass optimization framework and available tools are summarized with examples. The outlook and perspective for further glass property model development and formulation approaches are discussed.

Lu, Xiaonan↗
DOE OSTI2023

An Initial Evaluation of the Elevated-Temperature Cyclic Properties of Optimized 316H Stainless Steel Fabricated by Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy hot isostatic pressing (PM-HIP) is a mature advanced manufacturing technology, which can consolidate metallic powder under high temperature and pressure to generate near-net shape components. This process can lower production costs and reduce component lead times for nuclear reactor construction and can be readily deployed in the near term for microreactor components because of their smaller size. The purpose of this work is to continue the evaluation of elevated-temperature cyclic material properties for PM-HIP 316H stainless steel. Prior scoping results have shown that the commercially procured PM-HIP stainless-steel materials have reduced creep-fatigue performance compared to wrought 316 stainless steels. To better understand how PM-HIP processed material properties compare to traditional manufacturing methods, additional billets of PM-HIP 316H stainless steel were procured and tested. This testing is necessary to understand how elevated-temperature properties are influenced by the PM-HIP process and what data are needed for incorporating PM HIP 316H into the American Society of Mechanical Engineers Boiler Pressure Vessel Code, Section III, Division 5 for high temperature reactor construction. Specifically, an additional PM-HIP 316H stainless steel billet with lower oxygen and nitrogen concentrations was fabricated by the Nuclear Advanced Manufacturing Research Centre of the United Kingdom and tested to understand if elevated-temperature cyclic properties can be improved. The creep-fatigue resistance of the material from this new billet did not show appreciable improvement compared to prior testing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Thermal Shape Stability of fcc Metal Nanocrystals Synthesized with Faceted Nonequilibrium Shapes

Highly refined capabilities of the shape-controlled solution-phase synthesis of metal nanocrystals (NCs) allow the generation of NCs with faceted nonequilibrium shapes, which optimize properties for target applications such as catalysis and plasmonics. Often, for such applications and also for TEM analysis, the NCs are removed from the solution-phase environment. We explore the postsynthesis evolution of these metastable NCs in a high-vacuum TEM environment. Specifically, here we analyze their reshaping toward the equilibrium Wulff shapes mediated by surface diffusion, where such reshaping degrades the above-mentioned optimized properties. Typical sizes for these NCs range from 5 to 30 nm or 10 3 –10 6 atoms, and reshaping often occurs on the time scale of minutes for temperatures around, say, 400 °C. We discuss the development of predictive stochastic atomistic-level models for NC evolution with a realistic description of surface diffusion. These models, in contrast to Molecular Dynamics, can naturally address the relevant time and length scales for these systems. KMC simulation results for the stochastic models are described, focusing on the reshaping of slightly elongated nanorods and of mildly truncated octahedra and nanocubes. In addition, we review appropriate theoretical formulations for reshaping, which involves the nucleation and growth on 2D islands or layers on outer facets of the NC. We note the limitations of classical nucleation theory in some scenarios and demonstrate the successes of a more fundamental and general master equation-based analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Crystal Structure and Atomic Vacancy Optimized Thermoelectric Properties in Gadolinium Selenides

Thermoelectric materials enable the energy conversion of waste heat into electricity, helpful to relieve global energy crisis. Here, we report a systematic investigation on high-temperature thermoelectric gadolinium selenides, cubic Gd 3-x Se 4 (x = 0.16, 0.21 and 0.25) and orthorhombic Gd 2 Se 3-y (y = 0.02, 0.06 and 0.08). High energy synchrotron x-ray diffraction and total scattering have been used to investigate the crystallographic and local structures. Atomic-scale clusters of Gd vacancy in the cubic phase are observed by employing the reverse Monte Carlo simulation. For cubic Gd 3-x Se 4 , adjusting Gd vacancy triggers the effect of multiple conduction bands, confirmed by the increase in effective masses and theoretical calculations. A reasonable peak zT value of 0.27 is achieved at 850 K for Gd 3-x Se 4 (x = 0.16). On the other hand, tuning Se vacancy enables the optimization of electron concentration for the orthorhombic Gd 2 Se 3-y . More significantly, its low deformation potential (Ξ = 12eV) gives rise to enhanced electron mobility and higher peak zT value of 0.54 at 850 K for Gd 2 Se 3-y (y = 0.02). Intriguingly, a higher zT of 1.2 at 1200 K is reasonably predicted by quality factor analysis. Finally, this work extends the scope of high-temperature thermoelectric materials and facilitates the exploration of novel high-temperature thermoelectric materials

36 MATERIALS SCIENCE↗
DOE OSTI2020

Molten Chloride Thermophysical Properties, Chemical Optimization, and Purification

Next-generation concentrating solar power (CSP) technology requires high-temperature heat-transfer fluids and thermal energy storage that can operate in the temperature range of 500°–720°C. This high temperature demands a new chemistry for the heat-transfer fluids that must have high-temperature thermal and chemical stabilities, high energy density, and low corrosion rate on metallic materials used in the heat exchangers, piping, and thermal energy storage tanks. A ternary MgCl 2 -KCl-NaCl chloride-salt system has been proposed to achieve such goals, given its high-temperature thermal stability. The chloride-salt-based systems have been used by the metallurgy industry as the electrolyte to electrolytically extract metallic magnesium. They have also attracted attentions from the nuclear industry for developing the molten salt fast reactors that can operate at close to atmospheric pressure and at higher temperature than traditional light-water reactors. However, the corrosion properties of the ternary salt are not well known. The corrosion mechanism is believed to be correlated to the presence of MgOHCl impurity at the operation temperature. MgOHCl is fundamentally caused by the hygroscopic nature of the MgCl 2 component. Therefore, the first key objective of this project is to understand the nature of the corrosiveness of the ternary chloride-salt system and its prevention by designing new lab-scale purification processes. Because of its importance, a working group called the Chloride Salt Collective across multiple U.S. Department of Energy national laboratories is established to gain experimental agreement on the corrosion behaviors. In addition, water generation during salt dehydration could lead to highly corrosive HCl/water mixture via a hydrolysis process between water and anhydrous MgCl 2 or MgCl 2 hydrates. MgOHCl will eventually be converted to MgO particulates regardless of the chemical path chosen (i.e., by thermal decomposition, chemical purification with an active metal, or electrochemical purification utilizing the reduction power of electron flows). Large MgO particles with high hardness can wear out bearing and bushing and even clog the delicate channels in the primary heat exchanger. Because of this, a second objective is to understand the chemistry behind salt purification and transfer the scientific understanding to a set of engineering know-how for large-scale salt melter design. Because there is limited information on the thermophysical properties and the sensitivity of these properties around the targeted salt composition, a third objective is to measure thermophysical properties relevant to system and component design and support Topic 1 Liquid Pathway development. For example, composition shift due to salt reaction with water can be a potential issue because it can lead to changes of thermophysical properties, such as (1) melting point (or freeze point), which can jeopardize safe operation of the supercritical CO 2 power cycle proposed for next-generation CSP, and (2) heat capacity and density, which can decrease the overall power-generation capability of the plants. The value of the thermal conductivity of the selected salt composition is also a critical criterion for the solar receiver design.

14 SOLAR ENERGY↗
DOE OSTI2025

Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

High-pressure die cast (HPDC) AZ91 magnesium alloy is widely used in automotive components such as transmission housings and brackets for its excellent strength-to-weight ratio. Zinc-based cold spray coatings can be applied selectively to vulnerable areas to enhance corrosion resistance, minimize galvanic coupling with dissimilar metals, and eliminate the need for full-surface oxide coatings, making the process more efficient and targeted. A comprehensive evaluation of 16 combinations of nitrogen carrier gas temperatures and pressures led to the identification of an optimal range of process parameters, yielding Zn coatings with porosity <0.5 % by area, wear rates reduced by a factor of two compared to uncoated AZ91, and adhesion strengths up to 35 MPa. The enhanced mechanical performance of the coating is attributed to the low porosity and the formation of a metallurgical bond at the coating-substrate interface. Corrosion studies using macroscale potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) revealed a significant decrease in corrosion rate and a shift to more noble corrosion potentials (ZCP) for coated substrates. Furthermore, the Zn cold-sprayed samples exhibited significantly lower corrosion-induced evolved hydrogen content compared to the base AZ91 substrate and AZ91 coated with industrial coatings, demonstrating that the Zn layer effectively protects the substrate from the corrosive environment. Overall, cold spray Zn coatings significantly improve the mechanical and corrosion performance of AZ91 Mg alloys, addressing key material challenges and enabling their broader use in automotive applications.

Corrosion performance↗
DOE OSTI2026

Leveraging Stereochemistry to Optimize the Properties of Polyhydroxyalkanoates

The recycling of low-density polyethylene (LDPE) is challenging due to difficulties with sorting and contamination, leading to environmental harm. Polyhydroxyalkanoates (PHAs) are at the forefront of high-performance biodegradable alternatives to olefinic plastics, but few offer LDPE-like properties such as low strength and crystallinity while maintaining high ductility and thermal stability. Herein, we report a series of isoenriched transpoly( 3-hydroxy-2-methylbutyrates) (trans-PHMBs) with tunable mechanical and thermal properties. These polymers were synthesized through ring-opening polymerization of racemic trans-3,4-dimethylpropiolactone (rac-trans-DMPL), sourced from C1 and C4 feedstocks, using a new class of “sandwich” C 2 symmetric rac-( Ar BDI*)ZnO i Pr catalysts (where BDI = β-diketiminate). Variation of aromatic groups (Ar) and polymerization temperature yielded mm%s between 45−79% and melting temperatures (T m ) between 141−174 °C. trans-PHMB with intermediate isotacticities of 73 and 75 mm% exhibit similar stress−strain profiles to LDPE, indicating that these polymers have the potential to serve as higher melting, degradable substitutes for LDPE.

Biopolymers↗
DOE OSTI2025

Curiosity driven exploration to optimize structure–property learning in microscopy

Rapidly determining structure–property correlations in materials is an important challenge in better understanding fundamental mechanisms and greatly assists in materials design. In microscopy, imaging data provides a direct measurement of the local structure, while spectroscopic measurements provide relevant functional property information. Deep kernel active learning approaches have been utilized to rapidly map local structure to functional properties in microscopy experiments, but are computationally expensive for multi-dimensional and correlated output spaces. Here, we present an alternative lightweight curiosity algorithm which actively samples regions with unexplored structure–property relations, utilizing a deep-learning based surrogate model for error prediction. We show that the algorithm outperforms random sampling for predicting properties from structures, and provides a convenient tool for efficient mapping of structure–property relationships in materials science.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tailoring additive manufacturing to optimize dynamic properties in 316L stainless steel

With the advent of additive manufacturing, manipulation of typical microstructural elements such as grain size, texture, and defect densities is now possible at a faster time scale. While the processing–structure–property relationship in additive manufactured metals has been well studied over the past decade, little work has been done in understanding how this process affects the dynamic behavior of materials. We postulate that additive manufacturing can be used to alter the material microstructure and used to enhance its dynamic strength. In this work, 316L stainless steel (SS) was manufactured via selected laser melting and its microstructure was altered through changing build parameters like laser power, speed, and hatch spacing systematically. These samples were then subjected to spall recovery experiments to measure the spall strength and quantify the amount of damage as a function of build parameters. By mapping the spall strength as a function of build parameters, this work demonstrated that indeed additive manufacturing can be used to tailor the spall strength of 316L SS. This work also determined the optimum build parameters (laser power=195W; scanning speed=1083mm/s; hatch spacing=0.09mm; layer thickness=0.02mm) to obtain the highest spall strength and the least amount of total damage in 316L SS. Microstructural characterization of the pre- and post-mortem samples revealed that increased grain average misorientation and textural index were the main driving force behind this higher spall strength. This work aims to enhance microstructural engineering techniques to design materials with greater resistance to dynamic shock loading.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Modeling of Euclidean braided fiber architectures to optimize composite properties

Three-dimensional braided fiber reinforcements are a very effective toughening mechanism for composite materials. The integral yarn path inherent to this fiber architecture allows for effective multidirectional dispersion of strain energy and negates delamination problems. In this paper a geometric model of Euclidean braid fiber architectures is presented. This information is used to determine the degree of geometric isotropy in the braids. This information, when combined with candidate material properties, can be used to quickly generate an estimate of the available load-carrying capacity of Euclidean braids at any arbitrary angle.

Armstrong-Carroll, E.↗
DOE OSTI2020

Achieving High‐Performance and 2000 h Stability in Anion Exchange Membrane Fuel Cells by Manipulating Ionomer Properties and Electrode Optimization

The primary function of the ionomers that are incorporated into fuel cell electrode catalyst layers is to provide pathways for ion transport between the catalyst active sites and the electrolyte. This is influenced by many variables, including the ion-exchange capacity, water uptake, and molecular weight. In anion exchange membrane fuel cells (AEMFCs), controlling ionomer water uptake is particularly important and tailoring this property in each electrode is an important consideration when looking to maximize cell performance. In this study, three poly(norbornene) tetrablock copolymer ionomers with a range of physical properties are synthesized and incorporated into AEMFC anode and cathode electrodes. Systematic electrode engineering with these ionomers allows the peak power density to be increased by 100% (1.6 W cm -2 → 3.2 W cm -2 ) and the current density at 0.2 V to be increased by 59% (5.9 A cm -2 → 9.4 A cm -2 ). Moreover, the top-performing electrode configuration is tested in an operating AEMFC at the US Department of Energy defined current density of 600 mA cm -2 for 2000 h, showing a record-low voltage decay rate of 15.36 µV h -1 – only 3.65% –a over 2000 h. Here, this work sets a new bar for AEMFCs, reporting the best combination of performance and durability of any AEMFC to date.

08 HYDROGEN↗