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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Impacts of the Additive Manufacturing Process on the Roughness of Engine Scale Vanes and Cooling Channels

Abstract By leveraging the additive manufacturing (AM) platform, development time and costs for turbine component testing can be reduced relative to traditional investment casting. Surface roughness is a key characteristic of the additive manufacturing process that can impact flow, heat transfer, and mechanical integrity of printed components. There are multiple design and build considerations that result in variability in surface roughness, especially when additively fabricating complicated three-dimensional vanes and internal cooling passages. This study characterizes the surface roughness of internal cooling passages, vanes, and flat external surface samples made using additive manufacturing, specifically the direct metal laser sintering process. The samples were manufactured with various wall thicknesses, layer thicknesses, build locations, build directions, and on different AM machines. A combination of computed tomography scanning and optical profilometry was used to evaluate surface roughness levels. The data indicate that the dominant factors in roughness for a given layer thickness are a function of wall thickness, build location, and build direction.

Engineering↗
DOE OSTI2021

A Transformational Natural Gas Fueled Dynamic SOFC for Data Center in-Rack Power (Final Technical Report)

Data centers consume 250TWh or 1% of global electricity use in 2019. This electricity demand is expected to grow exponentially in the future. The current data center power supply relies on electric grids with diesel engines and batteries as backup; the latter is critically important because a sudden loss of power could erase crucial data, causing catastrophic economic loss. However, such a double protection architecture is costly, inefficient and polluting. In search for better in-rack power system, fuel-cell based generators have recently emerged as a promising alternative to diesel engines and batteries because of its potential to be more cost-effective, more efficient and less polluting. Among many types of fuel cells, solid oxide fuel cells stand out to be a front runner because of their ability to directly operate on natural gas that has an existing infrastructure. However, there are several critical challenges facing SOFC generators to meet the rigorous power requirements of data centers: high cost, poor reliability and more importantly, slow response to the datacenters’ dynamic load change. The unexpected overload conditions in data centers can cause fuel starvation; the latter can initiate microcracks in the anode structure, thus jeopardizing the lifetime of the SOFC generator. The current efforts to increase transient power capabilities of traditional SOFCs and therefore protect SOFC stacks from internal damage during transient loading, rely primarily upon mathematical algorithms. One of the challenges to these control methodologies is the physical limitations of the fuel delivery system such as slow response of mass flow controllers to fast power demand.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Pressure safety approach for PIP-II cryogenic distribution system and cryomodules

The Proton Improvement Plan-II (PIP-II) is a superconducting linear accelerator being built at Fermilab that will provide 800 MeV proton beam for neutrino production. The linac consists of a total of twenty-three (23) cryomodules of five (5) different types. Cooling is required at 2K, 5K and 40K. The Cryogenic Distribution System (CDS) consists of a Distribution Valve Box, ~285 m of cryogenic transfer line, modular Bayonet Cans to interface with cryomodules, and a Turnaround Can. The cryogenic system must provide protection from over-pressure by sizing pressure relief devices for all volumes and process line circuits. The cryomodule cavity circuits have dual pressure ratings, 4.1 bara when cold and 2.05 bara when warm (T>80K). Worst case relieving cases will be identified. The methods for determining heat flux will be presented. For the relieving occurring in the linac tunnel, flow must vent to outside to avoid an oxygen deficiency hazard. Also, we will present vacuum vesse l relief sizing to protect the cryogenic distribution system vacuum shells from over pressure during an internal line rupture. The project is funded by US DOE Offices of Science, High Energy Physics.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Conjugate Heat Transfer Modeling of Salt-Filled Fuel Pins for Stable Salt Reactor Safety Analysis

The Stable Salt Reactor (SSR) combines the proven structural design of light water reactor fuel assemblies with the inherent safety and fuel-cycle advantages of molten salt technology. In its fast reactor configuration, the SSR utilizes recycled nuclear waste as fuel, sealed within narrow salt-filled fuel pins and cooled by a surrounding liquid salt coolant. Reliable transfer of heat from the molten fuel salt through the cladding to the external coolant is essential for both reactor safety and performance. This work investigates conjugate heat transfer (CHT) in the SSR’s salt-filled fuel pins using NekRS, a high-fidelity spectral element computational fluid dynamics (CFD) solver. The analyses capture internal natural convection within the molten fuel salt and external forced convection in the coolant, under steady-state and transient operating conditions. Parametric studies evaluate how variations in reactor power and coolant flow rate influence heat transfer distributions and system response. The high-fidelity CFD results are time-averaged and post-processed for direct comparison with moderate-fidelity Reynolds-averaged Navier–Stokes (RANS) models, and for the development of reduced-order models within the SAM system code. These validated models support fast-running safety analyses of normal and off-normal transients, improving predictive capability for key safety margins. By integrating advanced CFD with system-level safety tools, this study strengthens the modeling framework for SSR design, reduces uncertainty in molten salt CHT simulations, and accelerates the engineering and licensing of next-generation nuclear reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

NGC 6302: The Tempestuous Life of a Butterfly

Abstract NGC 6302 (The Butterfly Nebula) is an extremely energetic and rapidly expanding bipolar planetary nebula (PN). If the central source is a single star, then its apparent location in an H-R diagram places it among the most massive, hottest, and presumably rapidly evolving of all central stars of PNe. Our proper motion study of NGC 6302, based on Hubble Space Telescope WFC3 images spanning 11 yr, has uncovered at least four different pairs of uniformly expanding internal lobes ejected at various times and orientations over the past two millennia at speeds ranging from 10–600 km s −1 . In addition, we find a pair of collimated off-axis flows in constant motion at ∼770 ± 100 km s −1 within which bright [Feii]feathersare conspicuous. Combining our results with those previously published, we find that the ensemble of flows has an ionized mass >0.1M ⊙ and its kinetic energy, between 10 46 and 10 48 erg, lies at the upper end of gravity-powered PNe ejection processes such as stellar mergers or mass accretion. We assemble our results into a plausible historical timeline of ejections from the nucleus and suggest that the ejections are powered by gravitational infall.

Astronomy & Astrophysics↗
DOE OSTI2024

Experimental Study on Flow Condensation of Low Global Warming Potential Refrigerants in a Micro-fin Aluminum Tube

This study investigates the dynamic shifts in refrigerant technologies driven by environmental regulations, particularly emphasizing low global warming potential (GWP). Moreover, there is a rising trend in the adoption of aluminum tubes with internal axial micro-fin structures in heat exchangers to reduce costs. The research focuses on the condensation process within an expanded axial micro-fin aluminum tube with a 5.96 mm fin-tip diameter. Various refrigerants are analyzed, including both single compounds (R-32, R-1234yf, R-1234ze(E)) and zeotropic mixtures (R-454B, R-454C, R-455A). Experimental procedures cover a range of condensation temperatures (35~45 °C), reduced pressures (0.21~0.55), and mass fluxes (150~350 kg/(m² s)), providing crucial data on heat transfer coefficients (HTC) and frictional pressure gradient (FPG). This data is particularly significant for high-glide refrigerants and is instrumental in the design of advanced air conditioning and refrigeration systems aimed at mitigating global warming.

Hu, Yifeng↗
DOE OSTI2024

Streamlining latent spaces in machine learning using moment pooling

Many machine learning applications involve learning a latent representation of data, which is often high-dimensional and difficult to directly interpret. In this work, we propose “moment pooling,” a natural extension of deep sets networks which drastically decreases the latent space dimensionality of these networks while maintaining or even improving performance. Moment pooling generalizes the summation in deep sets to arbitrary multivariate moments, which enables the model to achieve a much higher effective latent dimensionality for a fixed learned latent space dimension. We demonstrate moment pooling on the collider physics task of quark/gluon jet classification by extending energy flow networks (EFNs) to moment EFNs. We find that moment EFNs with latent dimensions as small as 1 perform similarly to ordinary EFNs with higher latent dimension. This small latent dimension allows for the internal representation to be directly visualized and interpreted, which in turn enables the learned internal jet representation to be extracted in closed form. Published by the American Physical Society 2024

Gambhir, Rikab (ORCID:0000000251080448)↗
DOE OSTI2025

Steel Creek, Pen Branch, and D-Area Watershed Stream Gauging Stations

A network of stream gauging systems were installed in the Steel Creek, Pen Branch, D-Area Discharge Canal, and the D006 Stream in support of the groundwater modeling efforts for the P-Area Groundwater Operable Unit (OU); Chemical, Metals, and Pesticides (CMP) Pits OU; and the D-Area Watershed, respectively. Each location is monitored by a MACE Floseries3 FloPro data logger and a MACE doppler ultrasonic area/velocity sensor. Each stream gauging system is powered by an internal 12-volt battery supplied by a solar panel with a trickle charger. Information collected by each data logger is logged internally and telecommunicated via a cellular network to an online server for real time analysis and monitoring. The MACE doppler ultrasonic area/velocity sensor can measure stream depth and velocities to give output values of flow rates, total flow, net flow, and volumes. The water depth is measured by a ceramic pressure transducer located on the top of the sensor. The velocity is measured by a continuous wave doppler sensor to give an average velocity across the whole stream profile. This report discusses the equipment and methods used to install continuous stream gauging stations and provides a summary of data collected through FY2025.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Printable Fiber Reinforced Cement Composites – Feasibility Study

Additive manufacturing is enabling the manufacturability of structures with previously unattainable complexity or functionality, and there is growing interest in additive manufacturing of “printed” concrete structures. The focus of this Phase 1 Technical Collaboration (TC) project was to evaluate feasibility of printing hybrid cement composite structures reinforced with textile carbon fibers (tCF). This project leverages other (non-IACMI) projects on cement formulation and printing process development, as well as on the production process for tCF. This project’s primary focus was to explore cement composite mix design with textile carbon fibers to be manufactured by MonteFibre (TC partner) and evaluate suitable fiber-matrix interface or sizing for cement composites working with Michelman (TC Partner). This project supports IACMI’s goal of reducing the cost and embodied energy of carbon fiber composites. Cost is one of the fundamental challenges to carbon fiber reinforced cement composites. Cement is an extremely inexpensive material (approximately $\$$0.05/lb). Adding 1 wt% of conventional carbon fiber to cement quadruples its cost. Therefore, the need to use low-cost carbon fiber and ensure that the additional cost of the carbon fiber has a greater cost benefit to the final product. This was the first preliminary evaluation to integrate tCF reinforcement in cement composites, and such potential tCF utilization should significantly reduce materials cost. Cement composite production is energy and emissions intensive, thus by strengthening it less material will be required. Hence, the embodied energy and production time of the resulting structures will be reduced. Additionally, integrating these new materials into additive processes can enable selective use of the material in high load or stress areas. It is noteworthy that past work in this field of fiber reinforced cement composites did not consider the optimization of fiber-matrix interface using suitable sizing. Carbon fiber reinforcement offers potential added benefits of thermal conductivity (which affects cure rate) and flow behavior that could provide opportunities for site specific utilization of carbon fiber on hybrid cement structures (e.g. use the fiber reinforcement on outer surfaces to enhance strength and modulus and then infiltrating the internal structures with conventional concrete). MonteFibre was the industry lead and planned on supplying the tCF for this project. However, during the short Phase-1 duration of this project, MonteFibre was unable to produce tCF for this project due to manufacturing plant being off-line throughout the course of the project. The project team decided to pursue an alternate option which involved demonstrating printable concrete with steel fibers by the ORNL lead, Dr. Brian Post. The University of Tennessee collaboration team focused on evaluating the suitable chemical sizing for carbon fibers working with Michelman and also developed methods for material characterization of cement-based composites to evaluate the material response for compression, shear, flexure, and tension. The two milestones for University of Tennessee, Knoxville were realized related to identification of one sizing suitable for carbon fiber reinforced cement composite and developing data associated with mechanical behavior of unreinforced (neat) and carbon fiber reinforced cement composites. ORNL could not complete the task of carbon fiber reinforced printed cement composites due to the reasons mentioned earlier, but was able to replace tCF with steel fibers to demonstrate the feasibility of printing with fiber reinforced cement composites. The Project team reviewed possible sizing chemistry available in collaboration with Michelman for use on carbon fiber reinforcement in cement composites and concrete applications. Our initial goal was to identify a sizing most promising for formulation with textile carbon fibers (tCF) to deliver excellent mechanical properties in composite material state. Since tCF was not available for this project as originally envisioned, the team continued this task to identify a suitable sizing for carbon fiber applications by applying such sizing to lower cost carbon fibers currently available commercially from Zoltek called Panex fibers. At a future time this can be optimized for textile carbon fibers from Montefibre. The bulk of previous work on carbon fiber reinforced cement has neglected the importance of fiber-matrix adhesion on mechanical properties of the cement composite and identifying this missing link was an important accomplishment for future research. Tensile behavior of fiber reinforced concrete is important to evaluate in order to realize the dream of concrete products that do not need reinforcing steel. Important sample preparation and testing procedures were addressed in this study and it was concluded that substantial improvements in tensile behavior, without compromising compressive strength, and improved ductility can result from the use of carbon fiber reinforcement.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Back-Stress and Its Evolution during Primary Creep in Particle Strengthened Nickel Superalloys

According to Eshelby’s theory, inelastically inhomogeneous inclusions in a metallic matrix give rise to a distribution of internal stresses. In the case of particle strengthened materials, such as nickel base superalloys, the presence and evolution of this back-stress leads to various observable effects, such as primary creep, back-flow upon loading, and memory of prior deformation. This article presents the background of the concept of back-stress and how it applies to the scenario of creep. A derivation of an evolution equation for back-stress in the context of primary creep is also presented. The results from neutron diffraction with in-situ creep experiments on directionally solidified nickel superalloys are presented in order to demonstrate the validity of the proposed equation and the corollaries derived therefrom.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electrostatic gating of ion transport in carbon nanotube porins: A modeling study

Carbon nanotube porins (CNTPs) are biomimetic membrane channels that demonstrate excellent biocompatibility and unique water and ion transport properties. Gating transport in CNTPs with external voltage could increase control over ion flow and selectivity. Herein, we used continuum modeling to probe the parameters that enable and further affect CNTP gating efficiency, including the size and composition of the supporting lipid membrane, slip flow in the carbon nanotube, and the intrinsic electronic properties of the nanotube. Our results show that the optimal gated CNTP device consists of a semiconducting CNTP inserted into a small membrane patch containing an internally conductive layer. Moreover, we demonstrate that the ionic transport modulated by gate voltages is controlled by the charge distribution along the CNTP under the external gate electric potential. The theoretical understanding developed in this study offers valuable guidance for the design of gated CNTP devices for nanofluidic studies, novel biomimetic membranes, and cellular interfaces in the future.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A novel Doppler backscattering (DBS) system to simultaneously measure radio frequency plasma fluctuations and low frequency turbulence

A novel quadrature Doppler Backscattering (DBS) system has been developed and optimized for the E-band (60–90 GHz) frequency range using either O-mode or X-mode polarization in DIII-D plasmas. In general, DBS measures the amplitude of density fluctuations and their velocity in the lab frame. The system can simultaneously monitor both low-frequency turbulence (f < 10 MHz) and radiofrequency plasma density fluctuations over a selectable frequency range (20–500 MHz). Detection of high-frequency fluctuations has been demonstrated for low harmonics of the ion cyclotron frequency (e.g., 2f ci ~ 23 MHz) and externally driven high-frequency helicon waves (f = 476 MHz) using an adjustable frequency down conversion system. Importantly, this extends the application of DBS to a high-frequency spectral domain while maintaining important turbulence and flow measurement capabilities. This unique system has low phase noise, good temporal resolution (sub-millisecond), and excellent wavenumber coverage (k θ ~ 1–20 cm –1 and kr ≲ 30 cm –1 ). As a demonstration, localized internal DIII-D plasma measurements are presented from turbulence (f ≤ 5 MHz), Alfvenic waves (f ~ 6.5 MHz), ion cyclotron waves (f ≥ 20 MHz), as well as fluctuations around 476 MHz driven by an external high-power 476 MHz helicon wave antenna. In the future, helicon measurements will be used to validate GENRAY and AORSA modeling tools for prediction of helicon wave propagation, absorption, and current drive location for the newly installed helicon current drive system on DIII-D.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Editorial for the Collection "Preparatory Work for the American Wake Experiment (AWAKEN)"

The American WAKE experimeNt (AWAKEN) is a large field campaign focused on gathering observations for improved understanding of atmospheric and wind power plant flow physics, one of the outstanding needs for the wind energy community as described in the Science paper by Veers et al.1 "Grand challenges in wind energy." AWAKEN was planned over several years with an international consortium of numerous stakeholders, including national laboratories, academic researchers, wind turbine manufacturers, and wind farm operators. A highlight of the AWAKEN campaign is the extensive use of remote sensing instrumentation to characterize the atmosphere and its interactions with wind power plants, enabled by recent developments in lidar, radar, and thermodynamic profiling technology. Advanced modeling techniques like mesoscale and large-eddy simulations (LES) also played an important role in the preparation of the experiment and the interpretation of the experimental data collected. This special-topic issue for the Journal of Renewable and Sustainable Energy presents a collection of 12 papers that describe the preparatory work and some initial analyses from the AWAKEN campaign. An overview of the contents of the various papers in this special issue is provided in Sec. II.

17 WIND ENERGY↗
DOE OSTI2020

A phenomenological rate of injection model for predicting fuel injection with application to mixture formation in light-duty diesel engines

Fuel injection rate laws are one of the most important pieces of information needed when modeling engine combustion with computational fluid dynamics. In this study, a simple phenomenological model of a common-rail injector was developed and calibrated for the Bosch CRI2.2 platform. The model requires three tunable parameter fits, making it relatively easy to calibrate and suitable for injector modeling when high-fidelity information about the internal injector’s geometry and electrical circuit details are not available. Each injection pulse is modeled as a sequence of up to four stages: an injection needle mechanical opening transient, a full-lift viscous flow inertial transient, a Bernoulli steady-state stage, and a needle descent transient. Parameters for each stage are obtained as polynomial fits from measured injection rate properties. The model enforces total injected mass, and the intermediate stages are only introduced if the injection pulse duration is long enough. Experimental rates of injection from two separate campaigns on the same injector were used to calibrate the model. The model was first validated against measured injection rate laws featuring pilot injections, short partially premixed combustion pulses, and conventional diesel combustion injection strategies. Then, it was employed as an input to engine computational fluid dynamics simulations, which were run to simulate experiments of mixture formation in an optically accessible light-duty diesel engine. It was found that, though simple, this model is capable of predicting both pilot and main injection pulse mass flow rates well: the simulations yielded accurate predictions of in-cylinder equivalence ratio distributions from injection strategies for both partially premixed combustion and pilot injections. Also, once calibrated, the model produced appropriate results for a wide range of injected mass and rail pressure values. Finally, it was observed that usage of such a relatively simple model can be a good choice when high-fidelity injection rate input and highly detailed information of the injector’s geometry and operation are not available, particularly as noticeable discrepancies can be present also among different experimental campaigns on similar hardware.

42 ENGINEERING↗
DOE OSTI2022

Metal Hydride Compressor for High-Pressure (875 bar) Hydrogen Delivery

Metal hydride hydrogen compression utilizes a reversible heat-driven interaction of a hydride-forming metal alloy with hydrogen gas. This paper reports on the development of a laboratory scale two-stage Metal Hydride Compressor (MHC) system with a feed pressure of 150 bar delivering high purity H2 gas at outlet pressures up to 875 bar. Stage 1 and stage 2 AB 2 metal hydrides are identified based on experimental characterization of the pressure-composition-temperature (PCT) behavior of candidate materials. The selected metal hydrides are each combined with expanded natural graphite, increasing the thermal conductivity of the composites by an order of magnitude. These composites are integrated in two compressor beds with internal heat exchangers that alternate between hydrogenation and dehydrogenation cycles by thermally cycling between 20 °C and 150 °C. The prototype compressor achieved compression of hydrogen from 150 bar to 700 bar with an average flow rate of 33.6 g/hr.

08 HYDROGEN↗
DOE OSTI2021

Dynamic thermal behavior of polycrystalline LaB 6 hollow cathodes

Lanthanum hexaboride (LaB6) hollow cathodes have demonstrated a capability for long life operation, which is critical to many space exploration missions. Thermal characterization of LaB6 hollow cathodes has revealed lower than expected electron emitter temperatures when the cathode reaches a steady state. This phenomenon is observed at discharge currents ranging from 5 to 35 A and xenon mass flow rates of 5–25 SCCM in cathodes with three different orifice diameters. Thus, the currently accepted value of the work function for polycrystalline LaB 6 , 2.67 eV, does not describe well the emission characteristics of LaB6 hollow cathodes operating with internal gas discharges at a steady state. We use empirically measured temperatures combined with a model of the hollow cathode emitter and xenon discharge to estimate the value of the work function, yielding a value ranging from 2.1 to 2.44 eV. This lower work function value implies that LaB6 hollow cathodes are expected to have even longer lifetimes than previously anticipated, further establishing them as a more suited alternative to other conventional cathode technologies for the task of long duration travel. Direct measurements of the work function as a function of depth on a hollow cathode emitter using x-ray photoelectron spectroscopy and ion beam milling indicate that the work function decreases with depth. We postulate several mechanisms that could explain the observed work function enhancement. Altogether, our results have important implications to the design, study approach, and operation of LaB 6 cathodes and potentially other cathodes with hollow configuration. Finally, our work opens the question of why the work function is reduced upon interaction with Xe plasma.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Supercritical water desalination and oxidation (SCWDO): Effectiveness on complex solutions, technoeconomic, and CO 2 impact for produced water treatment

The modern energy-economy is increasingly causing the production of highly saline brines, including from produced water. Supercritical water desalination can concentrate and extract minerals from these brines, but the effects of mixed salt interactions, organic degradation with additives, and the technology's economics are not well understood at supercritical condition. The present study evaluated and experimentally studied an integrated supercritical water desalination and oxidation (SCWDO) process for treating real-produced water samples from oil/natural gas field. The complex interactions between the various anions and cations in produced water were extensively evaluated. Most of the divalent and trivalent ions were extracted below 250 °C while the majority of the monovalent salt were removed between 380 to 410 °C. The treated real produced water was of drinking water quality, with <500 mg/l of total dissolved solid (TDS) and with 100% organics removal. Furthermore, the heat liberated during the organic oxidation could be utilized internally and for electricity generation for enhanced the energy efficiency and lower cost of produced water treatment. With system optimization, the proposed SCWDO process can essentially be made a net zero energy process. A novel process flow diagram for the commercial scale self-powered hybrid SCWDO technology was proposed as a cost-effective produced water treatment to mitigate the environmental crises. Techno-economic analysis showed that produced water treatment cost with SCWDO can be reduced to 2–3 $/m 3 and can be up to 60 % cheaper to traditional deep well reinjection. Additionally, the proposed SCWDO process could achieve net negative CO 2 emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗