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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Conceptual Design of A 20 T Dipole Based on Hybrid REBCO/Nb 3 Sn Cos-theta Coil

This paper presents a design concept of an HTS/LTS hybrid dipole with 50 mm aperture and 20 T nominal field based on a cos-theta coil and a cold iron yoke. The HTS part of magnet coil uses REBCO Twisted Stacked Tape cable. The LTS part is graded and made of two Nb3Sn Rutherford cables. Due to high sensitivity of HTS/LTS coils to large stresses and strains at high fields, a Stress Management (SM) concept combined with the cos-theta coil geometry is used. The results of magnet magnetic analysis are presented and discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Durability Research Is Pivotal for Perovskite Photovoltaics

Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.

14 SOLAR ENERGY↗
DOE OSTI2023

A Novel Design for Improving the Control on the Stainless-Steel Vessel Welding Process for Superconducting Magnets

Stainless steel vessels see widespread use in superconducting magnets for particle accelerator applications. Their function varies in different magnet designs: they always provide the necessary liquid helium containment, but in some cases are also used to provide azimuthal prestress and can also be welded to the magnet end plate to provide additional longitudinal stiffness. A magnet designed with the bladder and key technology does not rely on the structural role of the vessel. They are structurally supported using azimuthally prestressed aluminum shells, and the longitudinal constraint by rods. In this case, the magnet designer would generally like to minimize the interaction between the magnet and the stainless-steel vessel and to minimize the coil stress variation due to the vessel. The stress state in the vessel and in the coil is a function of the circumferential interference, defined as the vessel azimuthal length minus the magnet circumference. The vessel and the magnet azimuthal length machining tolerances are relatively large resulting in significant stress variations in the superconducting coils. In this paper we introduce an interference control shim, which can significantly limit the stress variation of the coils for a given variation of the interference. The effectiveness of the interference-control shim is evaluated numerically on the MQXF, the low-β quadrupole for the High Luminosity LHC.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

A fast Fourier transform-based solver for elastic micropolar composites

This work presents a spectral micromechanical formulation for obtaining the full-field and homogenized response of elastic micropolar composites. The algorithm relies on a coupled set of convolution integral equations for the micropolar strains, where periodic Green’s operators associated with a linear homogeneous reference medium are convolved with functions of the Cauchy and couple stress fields that encode the material’s heterogeneity, as well as any potential material nonlinearity. Such convolution integral equations take an algebraic form in the reciprocal Fourier space that can be solved iteratively. In this vein, the fast Fourier transform (FFT) algorithm is leveraged to accelerate the numerical solution, resulting in a mesh-free formulation in which the periodic unit cell representing the heterogeneous material can be discretized by a regular grid of pixels in two dimensions (or voxels in three dimensions). For verification, the numerical solutions obtained with the micropolar FFT solver are compared with analytical solutions for a matrix with a dilute circular inclusion subjected to plane strain loading. The developed computational framework is then used to study length-scale effects and effective (micropolar) moduli of composites with various topological configurations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been developed to optimize the microstructure of short fiber thermoplastic composites (SFTs)with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. Here, the current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σ uts ) and IRT (≈54.1%σ uts ) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 hours of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

42 ENGINEERING↗
DOE OSTI2023

Transportation Fatigue Testing of the pHB650 Power Coupler Antenna for the PIP-II Project at Fermilab

The PIP-II Project will see international shipment of cryomodules from Europe to the United States, and as such, the shocks which can occur during shipment pose a risk to the internal components. Of particular concern is the coupler ceramic window and surrounding brazes, which can see relatively high stress during an excitation event. Since the antenna design is new, and because of the setback failure would create, a cyclic stress test was devised for the antenna. This paper presents the experimental methods, setup, and results of the test.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Microstructure & Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1)expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L.Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY2025activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging-induced degradation of tensile and fracture behavior in LPBF316H.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part II—Design Rules

The challenge of using existing ASME Section III, Division 5, class A metallic materials for the construction of structural components of advanced reactors with corrosive coolants could be mitigated by allowing designers to use cladding to protect the base material from corrosion. However, the existing Section III, Division 5 rules provide no guidance on the evaluation of strain accumulation and creep-fatigue damage in cladded components. The availability of design rules for cladded components that do not require long-term clad material testing could promote the application of the cladding approach to accelerate the deployment schedule of these advanced reactor systems. To avoid long-term properties for the clad materials Part I of this work proposes two approximate design analysis methods for two types of clad materials—soft clads that creep much faster and have lower yield stress than the class A base material, and hard clads that creep much slower and have higher yield stress than the class A base material. The proposed analysis methods approximate the response of a soft clad by treating it as perfectly compliant and of a hard clad by treating it as linear elastic. Based on these approximate design analysis strategies this Part II develops a complete set of design rules for class A components cladded with either soft or hard clad materials. In conclusion, Part II discusses the reasoning behind the proposed design rules and uses example finite element analyses of representative reactor components to illustrate the use of these design methods.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Lithium-Ion Battery Life Model with Electrode Cracking and Early-Life Break-in Processes

This paper develops a physically justified reduced-order capacity fade model from accelerated calendar- and cycle-aging data for 32 lithium-ion (Li-ion) graphite/nickel-manganese-cobalt (NMC) cells. The large data set reveals temperature-, charge C-rate-, depth-of-discharge-, and state of charge (SOC)-dependent degradation patterns that would be unobserved in a smaller test matrix. Model structure is informed by incremental capacity analysis that shows loss of lithium inventory and cathode-material loss as the dominant capacity fade mechanisms. The model includes terms attributable to solid-electrolyte interface (SEI) growth, electrode cracking, cycling-driven acceleration of SEI growth, and "break-in" mechanisms that slightly decrease or increase available Li inventory early in life. The study explores what mathematical couplings of these mechanisms best describe calendar aging, cycle aging, and mixed calendar/cycle aging. Various approaches are discussed for extracting relevant stress factors from complex cycling profiles to predict lifetime during real-world battery loads using models trained on constant-current laboratory test results. The complexity of the present human-driven model identification process motivates future work in machine learning to more widely search and statistically discern the optimal model that correctly extrapolates capacity fade based on physical knowledge.

25 ENERGY STORAGE↗
DOE OSTI2026

Dielectric Spectroscopy Cable NDE for Unequal Aging Over Different Lengths

This Pacific Northwest National Laboratory milestone report assesses the effect of unequal aging over different lengths of cable on dielectric spectroscopy (DS) bulk impedance measurements from the cable end. DS measurements can indicate the remaining useful life of cables; however, most benchmark tests are based on accelerated aging of the entire cable. If only a portion of the cable is exposed to a harsh environment (as is frequently the case), the DS measurement will indicate a significantly less-aged cable than if the entire cable were exposed to a uniform environmental stress. The DS measurement is primarily related to the intrinsic insulation material relative permittivity—typically between 1.5 and 3.0. Insulation aging increases permittivity and, correspondingly, the cable’s overall capacitance measured from the cable end. To judge the health of the overall cable system, operators are primarily interested in the condition of the most severely aged section since that is where a failure is most likely to occur. This can be expressed as the dimensionless relative permittivity of the severely aged section divided by the permittivity of a pristine cable. This relative permittivity is an intrinsic material parameter independent of cable length and can serve as a quantitative indication of the insulation condition. If the relative percentages of cable exposed to a harsh and benign environment are known, the DS measurement of the entire cable length, including both pristine and aged sections, can be compensated to predict the relative permittivity (relative to pristine permittivity) of the most severly aged segment. A test was performed on three 50 ft (16 m) cables with 10%, 50%, and 90% of the cable inside a thermal aging oven. Predictably, the aging effect on the DS response was greatest in the 90% sample, followed by the 50% sample, and then the 10% sample. The more interesting result is the ratio of the aged insulation permittivity to the pristine insulation permittivity. Based on prior work, an end-of-life cable has a value of approximately 1.35. If the relative percentages of pristine and severely aged cable lengths are known, and the total cable-length capacitance of the initial pristine cable and the combined pristine plus aged cable are known, the relative aged permittivity (ratio of aged section permittivity / pristine section permittivity) can be estimated. The relative cable lengths exposed to a harsh environment may be known or estimated based on plant layout drawings or cable reflectometry tests that can locate the oven entry and exit points. The compensation was verified using a lumped-parameter model to predict the aged-segment permittivity e2/e1, where e2 is the aged-segment permittivity and e1 is the pristine-segment permittivity. For all three percentages of aged cable lengths, the ratio was quite similar, as would be expected since all cable segments were exposed to the same aging environment. This ratio of aged permittivity to pristine permittivity can be compared to other damage indicating tests, including elongation at break, to assess cable condition.

ARENA Test Bed↗
DOE OSTI2022

Biochemical responses of hairgrass (Deschampsia caespitosa) to hydrological change

Plant growth and development are closely related to water availability. Water deficit and water excess are detrimental to plants, causing a series of damage to plant morphology, physiological and biochemical processes. In the long evolutionary process, plants have evolved an array of complex mechanisms to combat against stressful conditions. In the present study, the duration-dependent changes in ascorbate (AsA) and glutathione (GSH) contents and activities of enzymes involved in the AsA-GSH cycle in hairgrass ( Deschampsia caespitosa ) in response to water stress was investigated in a pot trial using a complete random block design. The treatments were as follows: (1) heavily waterlogging, (2) moderate waterlogging, (3) light waterlogging, (4) light drought, (5) moderate drought, (6) heavily drought, and (7) a control (CK) with plant be maintained at optimum water availability. The hairgrass plants were subjected to waterlogging or drought for 7, 14, 21 and 28 days and data were measured following treatment. Results revealed that hairgrass subjected to water stress can stimulate enzymatic activities of ascorbate peroxidase (APX), glutathione peroxidase (GPX), glutathione reductase (GR), dehydroascorbate reductase (DHAR), monodehydroascorbate reductase (MDHAR) and L-galactono-1, 4-lactone dehydrogenase (GalLDH), switched on the ascorbate-glutathione (AsA-GSH) cycle and the L-galactose synthesis, up-regulated the contents of AsA and GSH, and maintained higher ratios of ascorbate to dehydroascorbate (AsA/DHA) and reduced glutathione to oxidized glutathione (GSH/GSSG) to alleviate potential oxidative damage. However, the light waterlogging did not induce hairgrass under stress to switch on the AsA-GSH pathway. In general, the critic substances and enzyme activities in AsA-GSH metabolic pathway increased as the increase of water stress intensity. As the increase of exposure duration, the critic antioxidant substances content and enzyme activities increased first and then maintained a relatively stable higher level. Our findings provide comprehensive information on biochemical responses of hairgrass to hydrological change, which would be a major step for accelerating ecological restoration of degradation alpine marshes in the Qinghai-Tibetan Plateau.

Luo, Qiaoyu↗
DOE OSTI2025

Microstructure and Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1) expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5 of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L. Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY 2025 activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging induced degradation of tensile and fracture behavior in LPBF 316H.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Propagation of Cryogenic Thermal Fractures from Unconfined PMMA Boreholes

In cryogenic fracturing, a rock surface exposed to cryogenic fluids undergoes a large thermal gradient, and the resultant local tensile stress overcomes rock strength and initiates fractures. This study investigates the development of cracks generated from the cryogenic treatment of a borehole under no external confining stress on specimens. The experiments were performed on transparent PMMA specimens to observe fracture proliferation around boreholes. Liquid nitrogen was flowed through the boreholes to cool the borehole surface. The results show that initial fracture growth is characterized by abrupt starts and stops, and as the fracture propagates outward, the growth appears more continuous. In an early stage, horizontal/radial fractures and vertical fractures are the defining patterns. Horizontal fractures tend to be separated by a specific exclusion distance (i.e., spacing between cracks). While distinct horizontal/vertical fractures and exclusion distance manifest themselves at an early stage, fractures resulting from fracture interactions and curvatures can develop into complex shapes at later stages. Cryogenic thermal loading induces distinctively curved fractures. The tendency of curvature may prevent greater penetration. An increase in the borehole pressure during liquid nitrogen flow, however, can lessen fracture tortuosity and facilitate radial propagation. A high flow pressure and rate are also advantageous in that they accelerate cooling and fracture propagation.

42 ENGINEERING↗
DOE OSTI2020

Recent California tree mortality portends future increase in drought-driven forest die-off

Vegetation tolerance to drought depends on an array of site-specific environmental and plant physiological factors. This tolerance is poorly understood for many forest types despite its importance for predicting and managing vegetation stress. We analyzed the relationships between precipitation variability and forest die-off in California's Sierra Nevada and introduce a new measure of drought tolerance that emphasizes plant access to subsurface moisture buffers. We applied this metric to California's severe 2012-2015 drought, and show that it predicted the patterns of tree mortality. We then examined future climate scenarios, and found that the probability of droughts that lead to widespread die-off increases threefold by the end of the 21st century. Our analysis shows that tree mortality in the Sierra Nevada will likely accelerate in the coming decades and that forests in the Central and Northern Sierra Nevada that largely escaped mortality in 2012-2015 are vulnerable to die-off.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

A System-Level Model for Estimating Residual Strain and Life of Nuclear Reactor Coolant System Components Under Connected-System-Thermal–Mechanical Boundary Conditions

Background: Environmental-assisted fatigue (EAF) is a major issue for the long-term survival of nuclear power plant fleets in the U.S. and worldwide. Multi-material welded regions (e.g., nozzles) and other high-stress regions of reactor coolant system (RCS) components are prone to EAF-related damage. Objective: The discussed work describes a system-level finite element (FE) model of RCS components of a pressurized water reactor (PWR). This is with the goal of predicting the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Methods: Herein, the FE model was developed considering system-level loading conditions (under connected system thermal-mechanical boundary conditions). Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the FE model results, the strain residuals, strain amplitudes and resulting fatigue lives of RCS components were predicted. Results: The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. Higher residual strain can lead to accelerated cyclic hardening of material and the associated effect of EAF. The simulated component-level strain profile (under realistic multi-axial-multi-physics loading cycle) can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests, which is a focus of future works. Conclusions: Despite similar geometry and material the RCS component can have significantly different strain profiles and resulting fatigue lives. The discussed approach can help to identify and prioritize the RCS components for conducting expensive nondestructive evaluation (NDE) inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Utilizing plant synthetic biology to accelerate plant-microbe interactions research

Plant-microbe interactions are critical to ecosystem resilience and substantially influence crop production. From the perspective of plant science, two important focus areas concerning plant-microbe interactions include: 1) understanding plant molecular mechanisms involved in plant-microbe interfaces and 2) engineering plants for increasing plant disease resistance or enhancing beneficial interactions with microbes to increase their resilience to biotic and abiotic stress conditions. Molecular biology and genetics approaches have been used to investigate the molecular mechanisms underlying plant responses to various beneficial and pathogenic microbes. While these approaches are valuable for elucidating the functions of individual genes and pathways, they fall short of unraveling the complex cross-talk across pathways or systems that plants employ to respond and adapt to environmental stresses. Also, genetic engineering of plants to increase disease resistance or enhance symbiosis with microbes has mainly been attempted or conducted through targeted manipulation of single genes/pathways of plants. Recent advancements in synthetic biology tool development are paving the way for multi-gene characterization and engineering in plants in relation to plant-microbe interactions. Here, we briefly summarize the current understanding of plant molecular pathways involved in plant interactions with beneficial and pathogenic microorganisms. Then, we highlight the progress in applying plant synthetic biology to elucidate the molecular basis of plant responses to microbes, enhance plant disease resistance, engineer synthetic symbiosis, and conduct in situ microbiome engineering. Lastly, we discuss the challenges, opportunities, and future directions for advancing plant-microbe interactions research using the capabilities of plant synthetic biology.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Magneto-Mechanical Optimization of Cross-Sections for $ \text{cos}(\theta)$Accelerator Magnets

The cross-section design of cos (θ) superconducting magnets is historically developed in a two-step process: initially, the coil geometry is defined on the basis of magnetic optimizations; then, the structure is designed around the coil. The first step searches for the best coil cross-section maximizing the magnetic field, margin, field quality and conductor efficiency. The latter step aims at limiting the coil stresses and deformations. However, the coil design, defined with the initial magnetic optimization, can influence the mechanical behaviour of the magnet, altering, for example, the peak stress during operation. As the critical current is a function of the applied strain, the mechanical implications of the coil cross-section design can limit the achievable performance. In this paper we propose an integrated optimization process that targets the peak stress on the conductor in addition to the magnetic objectives. Here the results are presented for a sample high-field Nb 3 Sn dipole: a 4-layer design aiming at ultimate conductor performance.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗