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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Standard Analytical Methods for Pyrolysis Bio-Oils

There has been significant recent interest in the production of renewable fuels and chemicals from biomass and waste feedstocks. Pyrolysis pathways produce a liquid bio-oil product, which must be processed further, or upgraded, to yield fuel or chemical products. Bio-oils are very complex and often unstable samples, and research and development on upgrading processes needs reliable analytical information. In particular, chemical characterization techniques are needed to quantify both functional groups and individual compounds present in bio-oils. Reliable analytics are also needed to enable the bioenergy industry, as industrial facilities often have different analytical needs and capabilities than research facilities. In this presentation, we will discuss the development of a suite of standard analytical methods for pyrolysis bio-oils. Analytical methods to be discussed include: Determination of Carbon, Hydrogen, Nitrogen, and Oxygen in bio-oils; Accelerated Aging of Fast Pyrolysis Bio-oil using Carbonyl Titration; Determination of Water Content in Bio-oils by Volumetric Karl Fischer Titration; Determination of Carbon Functional Groups; Elemental Analysis of Bio-oils by Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) - Na, K, Mg, Ca, S, P, and Fe; Determination of Phenolic Groups in Bio-oils using Revised Folin-Ciocalteu Methods: Single Cuvette and Plate Reader; Corrosivity of Bio-oils: Screening Test using Metal Leaching; Determination of Biogenic Content by 14C Measurement using Liquid Scintillation Counter. These new analytical methods are publicly available as Laboratory Analytical Procedures (https://www.nrel.gov/bioenergy/bio-oil-analysis.html), along with previously developed standard methods: GC-MS, Acid Titration, Carbonyl Titration, and 31P NMR. Additionally, the development of diffusion ordered NMR for characterization of bio-oil molecular weight will be discussed. Collectively, this suite of analytical methods represents the most comprehensive set of standard methods available for pyrolysis bio-oils. These standard methods are commonly used by the bioenergy community, and provide reliable information that enables research, scaleup, and industrial processing of biomass to produce renewable fuels and chemicals.

analytical↗
DOE OSTI2023

Heat Exchanger Design for Waste Heat Recovery using Additive Manufacturing

With anticipated increases in global energy use and their associated emissions, there are many efforts to improve the emissions and efficiency of many industrial processes through waste heat recovery (WHR). To maximize improvements, the heat exchangers in WHR power cycles must be designed and optimized for a given heat source. Meanwhile, additive manufacturing (AM) is a single part manufacturing technique that provides the opportunity to develop unique and complex heat exchanger designs. Consequently, this work centers on the modeling, design, optimization, and testing of AM shell and tube heat exchangers for WHR. Specifically, a modified one-dimensional (1+1-D) and three-dimensional (3-D) heat exchanger models were developed and validated, with the 1+1-D model serving as the basis for design optimization. After modifications to the design to allow for AM, heat exchanger geometry optimizations were completed, targeting increased effectiveness across a range of physical parameters. Of the designs considered, nine were additively manufactured using Ti5553, and then tested using an external heat source and working fluid. Experimentally, the nineteen-tube, zero-baffle heat exchanger displayed the best overall performance, with the effects of dimensional accuracy, surface roughness, and baffles in the other designs also indicated. Next, the experimental results were used as inputs for the 1+1-D model. Although the original model was able to predict fluid outlet temperatures within 5% differences, larger variations in the heat exchanger performance parameters, temperature differences, and pressure drop necessitated optimizing the pressure drop and heat transfer calculations within the model. Thus, the resulting improved model was able to predict the heat transfer rates, heat source temperature difference, and effectiveness within 15% differences, while showing improvements in the pressure drops and working fluid temperature differences. The improved model serves as the foundation for future work to improve the design and performance of AM heat exchangers.

Spickler, Bailey Ann↗
DOE OSTI2017

Risk Assessment and Management of Uranium Mill Tailings Legacies - 17508

exploitation activities took place at 61 sites. The great majority of these mining sites are located in central-east Portugal, including the Urgeirica mine that was the most important uranium deposit exploited in the country. The mining activities at this site generated 1.6 million m{sup 3} of radioactive wastes disposed in an open air area originating the largest radioactive tailings pile of the country. The environmental remediation of the Urgeirica site was one of the main priorities of the national plan for the rehabilitation of former uranium mining sites. Site remediation, that included the mine industrial area with several support infrastructures and a processing plant, was executed between 2006 and 2008 (1. phase) and between 2008 and 2014 (2. phase). Nevertheless, the environmental rehabilitation of the Portuguese uranium legacies sites is not yet concluded. One of the last largest mining complexes, the Quinta do Bispo open pit, is scheduled to be rehabilitated only in 2020. This work presents a study to evaluate the environmental impacts from the uranium mill tailings legacies before and after the remediation works, focusing on two different approaches: a deterministic methodology for dose assessment and a probabilistic methodology with the Monte Carlo method to estimate the incremental lifetime risk. Probabilistic distributions of the input parameters were used in the risk calculation approach. The methodology for dose and risk assessments may be applied to other sites that are still under intervention and the results may be used to prioritize the remediation stages. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Laser Powder Bed Fusion Additive Manufacturing In-Process Monitoring and Optimization Using Thermionic Emission Detection

In this project, the emission of electrons during laser powder bed fusion additive manufacturing was identified and investigated to resolve the underlying dynamics driven by laser-material interactions. Laser powder bed fusion involves the selective laser melting of metal powder particles layer by layer which fuse together forming a larger 3D structure. Laser-based additive manufacturing approaches such as laser powder bed fusion hold the potential to revolutionize manufacturing of complex metal components in the aerospace, medical, and automotive industries. However, the difficulty in producing defect-free components by metal 3D printing is a major hurdle for widespread commercial adoption. This project resolved important dynamics in laser powder bed fusion including the identification of plasma formation mechanisms, transitions between laser-induced melting modes and stochastic precursors to defect formation. These findings were realized through implementation of electronic sensing diagnostics into an existing testbed system and harnessing capabilities developed for the time dependent analysis of laser powder bed fusion datasets. Importantly, the results advance our understanding of laser-material interactions and reveal that detection of thermionic emission can also resolve information critical to optimization of the laser powder bed fusion fabrication process. The findings are critical for advancing our fundamental understanding of the laser powder bed fusion process and can help assure the requisite fidelity of fabricated components.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage (CRADA Report)

NREL and Element 16 collaborated on sulfur thermal energy storage modeling using NREL’s high performance computing (HPC) resources to assist its application in industrial processes. Industrial process heat (IPH) accounts for ~70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately, 1500 TWht (~60% Terawatt hour thermal) of IPH demand is in the temperature range of 100-300°C. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. This HPC4EI project facilitated Element 16’s development of low-cost and high-impact molten sulfur TES for dispatchable IPH. The development of a high-fidelity model validated by experimental data and HPC simulations enabled the successful resolution of the complex interplay between fluid dynamics and heat transfer processes during transient operation of sulfur TES, overcoming the numerical challenges posed by the non-linear temperature-dependent physical properties of sulfur. The project helped accelerate Element 16’s molten sulfur TES product design and support its broad applications.

25 ENERGY STORAGE↗
DOE OSTI2024

A review on machine learning-guided design of energy materials

Abstract The development and design of energy materials are essential for improving the efficiency, sustainability, and durability of energy systems to address climate change issues. However, optimizing and developing energy materials can be challenging due to large and complex search spaces. With the advancements in computational power and algorithms over the past decade, machine learning (ML) techniques are being widely applied in various industrial and research areas for different purposes. The energy material community has increasingly leveraged ML to accelerate property predictions and design processes. This article aims to provide a comprehensive review of research in different energy material fields that employ ML techniques. It begins with foundational concepts and a broad overview of ML applications in energy material research, followed by examples of successful ML applications in energy material design. We also discuss the current challenges of ML in energy material design and our perspectives. Our viewpoint is that ML will be an integral component of energy materials research, but data scarcity, lack of tailored ML algorithms, and challenges in experimentally realizing ML-predicted candidates are major barriers that still need to be overcome.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Robotic Assembly of SRF Cavity Pair

Superconducting Radio Frequency (SRF) cavities for particle accelerators require tight tolerances, ultrahigh vacuum, and strict cleanliness during assembly. As in the semiconductor industry, defects such as particles and residues are deleterious to performance, possibly rendering a cavity unfit for use. This problem is addressed primarily through cleanroom assembly during sensitive steps and rigorous chemical processing to prevent and remove such defects. Human workers are often the largest source of contamination, even with proper gowning and practices. The semiconductor industry has long integrated robots in cleanroom operation, but this has not occurred for SRF cavity production; SRF cavities, unlike wafers, are complex shapes, require more hands-on mechanical assembly, and are low-volume production items. At Jefferson Laboratory, a co-operative robot (cobot) has been setup to overcome these problems. Cobots are safe for use alongside human workers and can integrate new tools such as a 3D camera part detection and gripper for item manipulation. Therefore, cobots represent a promising avenue for reducing particulate generated during a variety of assembly tasks. A mockup of a cavity pair and coupler was setup and the cobot programmed to automatically pick up the coupler and place on the mating cavity flange. Particle counting methods were setup to measure human vs cobot assembly particulate generation inside a cavity mockup. Other potential uses will be discussed for further improving SRF cavity assembly steps, where a cobot can replace or assist a human operator, and what potential gains are expected.

Duzik, Adam [Thomas Jefferson National Accelerator↗
DOE OSTI2024

Advanced manufacturing and digital twin technology for nuclear energy*

Advanced manufacturing techniques and digital twin technology are rapidly transforming the nuclear industry, offering the potential to enhance productivity, safety, and cost-effectiveness. Customized parts are being produced using additive manufacturing, automation, and robotics, while digital twin technology enables the virtual modeling and optimization of complex systems. These advanced technologies can significantly improve operational efficiency, predict system behavior, and optimize maintenance schedules in the nuclear energy sector, leading to heightened safety and reduced downtime. However, the nuclear industry demands the highest levels of safety and security, as well as intricate manufacturing processes and operations. Thus, challenges such as data management and cybersecurity must be addressed to fully realize the potential of advanced manufacturing techniques and digital twin technology in the nuclear industry. This comprehensive review highlights the critical role of digital twin technology with advanced manufacturing toward nuclear energy to improve performance, minimize downtime, and heighten safety, ultimately contributing to the global energy mix by providing dependable and low-carbon electricity.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Oxygen and carbon in silicon

The properties of the early transistors were determined by the minority-carrier lifetime, as is the silicon photovoltaic solar cell. Most of the devices on the modern integrated circuits are majority carrier devices, in part to avoid this lifetime dependence. The micro-electronics industry typically starts with wafers with a minority-carrier lifetime of 1000 micro-seconds, but during device fabrication this lifetime is reduced to beflow 1 micro-second, in spite of extraordinary cleanliness and precautions. Process-induced defects (PID) include point defects, defect complexes, line defects, and bulk precipitates. One of the aspects that needs to be better understood is the nature of minority carrier recombination at line defects and at precipitates. Some of the PIDs are known to be related to the fast-diffusers of the iron-series transition elements. One of the common techniques of dealing with these elements is intrinsic gettering by the oxygen precipitates. But even in the gettered state, there may be a residual effect on the lifetime. Oxygen is an almost ubiquitous impurity in silicon and plays an important role in both integrated circuits and solar cells. The isolated oxygen interstitial is electrically inactive, but in its various aggregated forms it has a variety of electrical activities. The agglomeration and precipitation of oxygen, including impurity gettering and the complicating role of carbon, is discussed.

Corbett, J. W.↗
NASA NTRS2010

Electrostatic Separator for Beneficiation of Lunar Soil

A charge separator has been constructed for use in a lunar environment that will allow for separation of minerals from lunar soil. In the present experiments, whole lunar dust as received was used. The approach taken here was that beneficiation of ores into an industrial feedstock grade may be more efficient. Refinement or enrichment of specific minerals in the soil before it is chemically processed may be more desirable as it would reduce the size and energy requirements necessary to produce the virgin material, and it may significantly reduce the process complexity. The principle is that minerals of different composition and work function will charge differently when tribocharged against different materials, and hence be separated in an electric field.

Quinn, Jacqueline↗
DOE OSTI2018

Quantification of complex-phase steel microstructure by using combined EBSD and EPMA measurements

Highlights: • In CP800 steel, bainite is the dominant phase with a typical lath (width 300 nm) structure and cementite precipitates. • Martensite is dispersed as small islands and only a few narrowed martensite bands are observed which has been induced by annealing process of cold rolled sheet. • The precise carbon content is measured in bainite and martensite utilizing EPMA line scans, which is around 0.2 wt% and 0.4 wt%, respectively. • Digitalization of the microstructure for CP800 is achieved by combining EBSD and EPMA techniques. • The final constituent map consists of plenty of microstructural features including topography, crystal structures, orientations and elemental distribution. - Abstract: We combined electron backscatter diffraction (EBSD) and electron probe microanalysis (EPMA) techniques to characterize the microstructure of industrial produced complex-phase CP800 steel. First, three major constituents (ferrite, martensite and bainite) are characterized. Then, transformation-induced dislocation zones in ferrite and bainitic regions consisting of different sub-structures are quantified and segmented. A final digitalized component map including plenty of microstructural features including crystal structures, orientations and elemental distribution are successfully achieved. The precise carbon content is measured in bainite and martensite utilizing EPMA line scans, which is around 0.2 wt% and 0.4 wt%, respectively. In the bainite phase of CP800, a typical Bagaryatski orientation relationship between cementite and lath-like bainitic ferrite is revealed based on the select diffraction patterns of transmission electron microscopy measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling

Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.

Engineering↗
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Characterization of Refractory Alloys Produced by Laser Additive Manufacturing

Refractory alloys often possess superior thermomechanical properties compared to conventional materials, such as steels, Ni-based superalloys, and Ti alloys, especially in high-temperature environments. While these materials promise to revolutionize numerous industries, significant hurdles remain for insertion into applications due to an incomplete understanding of structure-property relationships and conventional processing challenges. We explore laser-based additive manufacturing (AM) to construct refractory alloys consisting of combinations of Mo, Nb, Ta, and Ti with systematically increasing compositional complexity. Microstructure, composition, and hardness of the AM-processed alloys were characterized. Results are discussed in the context of pairing additive manufacturing with refractory metals to enable next-generation alloys.

Kustas, Andrew B.↗
NASA NTRS1978

The natural and perturbed troposphere

A quantitative assessment of the chemical and climatic effects of industrial emissions into the atmosphere requires an understanding of the complex interactions of species within the atmosphere and of the atmosphere with other physical systems such as the oceans, lithosphere, and biosphere. The concentration of a particular species is determined by competition between various production and loss processes. The abundances of tropospheric gases are examined. The reactions of the members of the oxygen group are considered along with the models which have been developed to describe the involved relationships. Attention is also given to the natural carbon cycle, perturbations to the carbon cycle, the natural nitrogen cycle, perturbations to the nitrogen cycle, the hydrogen group, the sulfur group, and the halogen group.

Stewart, R. W.↗
NASA NTRS1991

High resolution ultrasonic spectroscopy system for nondestructive evaluation

With increased demand for high resolution ultrasonic evaluation, computer based systems or work stations become essential. The ultrasonic spectroscopy method of nondestructive evaluation (NDE) was used to develop a high resolution ultrasonic inspection system supported by modern signal processing, pattern recognition, and neural network technologies. The basic system which was completed consists of a 386/20 MHz PC (IBM AT compatible), a pulser/receiver, a digital oscilloscope with serial and parallel communications to the computer, an immersion tank with motor control of X-Y axis movement, and the supporting software package, IUNDE, for interactive ultrasonic evaluation. Although the hardware components are commercially available, the software development is entirely original. By integrating signal processing, pattern recognition, maximum entropy spectral analysis, and artificial neural network functions into the system, many NDE tasks can be performed. The high resolution graphics capability provides visualization of complex NDE problems. The phase 3 efforts involve intensive marketing of the software package and collaborative work with industrial sectors.

Chen, C. H.↗
NASA NTRS2011

Evolution of the Florida Launch Site Architecture: Embracing Multiple Customers, Enhancing Launch Opportunities

The impending conclusion of the Space Shuttle Program and the Constellation Program cancellation unveiled in the FY2011 President's budget created a large void for human spaceflight capability and specifically launch activity from the Florida launch Site (FlS). This void created an opportunity to re-architect the launch site to be more accommodating to the future NASA heavy lift and commercial space industry. The goal is to evolve the heritage capabilities into a more affordable and flexible launch complex. This case study will discuss the FlS architecture evolution from the trade studies to select primary launch site locations for future customers, to improving infrastructure; promoting environmental remediation/compliance; improving offline processing, manufacturing, & recovery; developing range interface and control services with the US Air Force, and developing modernization efforts for the launch Pad, Vehicle Assembly Building, Mobile launcher, and supporting infrastructure. The architecture studies will steer how to best invest limited modernization funding from initiatives like the 21 st elSe and other potential funding.

Colloredo, Scott↗
DOE OSTI2024

Prediction of residual stresses in additively manufactured parts using lumped capacitance and classical lamination theory

Several industries are interested in Laser Powder Bed Fusion (L-PBF) Additively Manufactured (AM) metal parts because their designs can be made arbitrarily complex while retaining bulk-type material properties. However, the residual stresses (RS) and distortions caused by the heat gradients inherent to L-PBF processes are detrimental to the structural integrity of the parts and must be taken into consideration during the part design cycle. Predicting the state of stresses in as-built 3D printed parts is a difficult problem that is typically approached with the use of transient thermomechanical Finite Element Models (FEMs). However, the nonlinearities associated with AM processes are difficult to capture in these FEMs without increasing the computational cost of the simulation, limiting their ability to be incorporated into practical design cycles. This work presents a novel analytical framework that combines lumped capacitance nonlinear heat transfer with time dependent classical lamination theory to efficiently and accurately predict RS in as-built L-PBF parts without the need of FEMs. The simulation was compared to Neutron Diffraction (ND) residual strain measurements taken at Oak Ridge National Laboratories (ORNL) as well as Synchrotron X-ray Diffraction (XRD) strain data published by the National Institute of Standards and Technology (NIST). The simulation predictions and the experimental data showed excellent agreement for the in-plane strain directions, and general agreement for the out of plane strain component, highlighting an area where further development can be implemented.

42 ENGINEERING↗