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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
NASA NTRS2002

Method of making silicon carbide-silicon composite having improved oxidation resistance

A Silicon carbide-silicon matrix composite having improved oxidation resistance at high temperatures in dry or water-containing environments is provided. A method is given for sealing matrix cracks in situ in melt infiltrated silicon carbide-silicon matrix composites. The composite cracks are sealed by the addition of various additives, such as boron compounds, into the melt infiltrated silicon carbide-silicon matrix.

Luthra, Krishan Lal↗
DOE OSTI2022

Ultra-high temperature carbide foams and methods of fabricating the same

Ultra-high temperature carbide (UHTC) foams and methods of fabricating and using the same are provided. The UHTC foams are produced in a three-step process, including UHTC slurry preparation, freeze-drying, and spark plasma sintering (SPS). The fabrication methods allow for the production of any kind of single- or multi-component UHTC foam, while also providing flexibility in the shape and size of the UHTC foams to produce near-net-shape components.

Agarwal, Arvind↗
DOE OSTI2023

Ultra-high temperature carbide foams and methods of fabricating the same

Ultra-high temperature carbide (UHTC) foams and methods of fabricating and using the same are provided. The UHTC foams are produced in a three-step process, including UHTC slurry preparation, freeze-drying, and spark plasma sintering (SPS). The fabrication methods allow for the production of any kind of single- or multi-component UHTC foam, while also providing flexibility in the shape and size of the UHTC foams to produce near-net-shape components.

Agarwal, Arvind↗
DOE OSTI2020

EXPERIMENTAL STUDY ON COST-EFFECTIVE ADDITIVE MANUFACTURING OF SILICA AEROGEL

The conventional aerogel insulation material manufacturing from supercritical drying suffers from issues of massive energy consumption and prolonged processing time. With the consideration of large market demand of the aerogel insulation material in the next decade, a low-cost and scalable fabrication technique is highly desired. In this paper, a direct ink writing (DIW) method is used to three-dimensionally fabricate the silica aerogel insulation material, followed by ambient pressure drying. Compared to the supercritical drying and freeze drying, the reported method significantly reduces the fabrication time and costs. The cost-effective DIW technique offers the capability to print complex hollow internal structure, coupled with the porous structure, is found to be beneficial to the thermal insulation property. The addition of fiber to the ink assures the durability of the fabricated product. The foam ink preparation methods and the printability are demonstrated in this paper, along with the printed samples for characterizing thermal insulation properties and mechanical properties.

42 ENGINEERING↗
DOE OSTI2013

Practical Considerations of Moisture in Baled Biomass Feedstocks

Agricultural residues make up a large portion of the immediately available biomass feedstock for renewable energy markets. Current collection and storage methods rely on existing feed and forage practices designed to preserve nutrients and properties of digestibility. Low-cost collection and storage practices that preserve carbohydrates across a range of inbound moisture contents are needed to assure the economic and technical success of the emerging biomass industry. This study examines the movement of moisture in storage and identifies patterns of migration resulting from several on-farm storage systems and their impacts on moisture measurement and dry matter recovery. Baled corn stover and energy sorghum were stored outdoors in uncovered, tarp-covered, or wrapped stacks and sampled periodically to measure moisture and dry matter losses. Interpolation between discrete sampling locations in the stack improved bulk moisture content estimates and showed clear patterns of accumulation and re-deposition. Atmospheric exposure, orientation, and contact with barriers (i.e., soil, tarp, and wrap surfaces) were found to cause the greatest amount of moisture heterogeneity within stacks. Although the bulk moisture content of many stacks remained in the range suitable for aerobic stability, regions of high moisture were sufficient to support microbial activity, thus support dry matter loss. Stack configuration, orientation, and coverage methods are discussed relative to impact on moisture management and dry matter preservation. Additionally, sample collection and data analysis are discussed relative to assessment at the biorefinery as it pertains to stability in storage, queuing, and moisture carried into processing.

09 BIOMASS FUELS↗
DOE OSTI2024

Mechanical and Electrochemical Implications of Drying Temperature on Lithium‐Ion Battery Electrodes

Abstract Lithium‐ion battery (LIB) electrodes are typically produced with n‐methyl‐2‐pyrrolidone, a toxic solvent that is a known carcinogen and reproductive hazard. Accordingly, aqueous processing has been an expanding area of research interest in the field of LIB manufacturing. Although aqueous processing has been widely successful in anode processing, serious challenges remain in processing the cathode. In this work, the drying mechanics of cathode processed with both solvents is investigated though implementation of a chemical‐engineering‐based model to better understand the utilization of heat provided by experimentally determining the heat and mass transfer coefficients. Electrochemical performance is also evaluated to determine the impact of drying temperature on cycling performance. Binder distribution is determined via various methods to confirm differences in binder homogeneity as a function of both solvent and drying temperature. Identified is the large difference in the efficiency in which the heat is used as well as an ideal drying temperature for both aqueous and non‐aqueous processed cathodes. Also identified is the increased sensitivity to processing temperature for aqueous processed electrodes compared to non‐aqueous processed counterparts, pointing to the possibility of tuned drying regimes which would capitalize on the potential cost savings of aqueous processing for cathodes.

25 ENERGY STORAGE↗
DOE OSTI2011

A GAMMA RAY SCANNING APPROACH TO QUANTIFY SPENT FUEL CASK RADIONUCLIDE CONTENTS

The International Atomic Energy Agency (IAEA) has outlined a need to develop methods of allowing re-verification of LWR spent fuel stored in dry storage casks without the need of a reference baseline measurement. Some scanning methods have been developed, but improvements can be made to readily provide required data for spent fuel cask verification. The scanning process should be conditioned to both confirm the contents and detect any changes due to container/contents degradation or unauthorized removal or tampering. Savannah River National Laboratory and The University of Tennessee are exploring a new method of engineering a high efficiency, cost effective detection system, capable of meeting the above defined requirements in a variety of environmental situations. An array of NaI(Tl) detectors, arranged to form a 'line scan' along with a matching array of 'honeycomb' collimators provide a precisely defined field of view with minimal degradation of intrinsic detection efficiency and with significant scatter rejection. Scanning methods are adapted to net optimum detection efficiency of the combined system. In this work, and with differing detectors, a series of experimental demonstrations are performed that map system spatial performance and counting capability before actual spent fuel cask scans are performed. The data are evaluated to demonstrate the prompt ability to identify missing fuel rods or other content abnormalities. To also record and assess cask tampering, the cask is externally examined utilizing FTIR hyper spectral and other imaging/sensing approaches. This provides dated records and indications of external abnormalities (surface deposits, smears, contaminants, corrosion) attributable to normal degradation or to tampering. This paper will describe the actual gathering of data in both an experimental climate and from an actual spent fuel dry storage cask, and how an evaluation may be performed by an IAEA facility inspector attempting to draw an independent safeguards conclusion concerning the status of the special nuclear material.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

A rejuvenation process to enhance the durability of low Pt loaded polymer electrolyte membrane fuel cells

Here, an effective method to enhance the durability of polymer electrolyte membrane fuel cells (PEMFCs) is reported. PEMFC performance loss is mitigated by exposing the electrodes of fuel cells to dry nitrogen gas periodically at high temperature. This method extends the lifetime of fuel cells significantly compared to their non-treated counterparts. The impact of treatment temperature and exposure time on PEMFC durability is reported, using potential cycling accelerated stress tests. The enhanced durability is attributed to the suppression of “ionomer relaxation” that occurs under the nearly water saturated operating conditions of a PEMFC cathode.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Characterization of spent nuclear fuel canister surface roughness using surface replicating molds

In this study we present a replication method to determine surface roughness and to identify surface features when a sample cannot be directly analyzed by conventional techniques. As a demonstration, this method was applied to an unused spent nuclear fuel dry storage canister to determine variation across different surface features. In this study, an initial material down-selection was performed to determine the best molding agent and determined that non-modified Polytek PlatSil23-75 provided the most accurate representation of the surface while providing good usability. Other materials that were considered include Polygel Brush-On 35 polyurethane rubber (with and without Pol-ease 2300 release agent), Polytek PlatSil73-25 silicone rubber (with and without PlatThix thickening agent and Pol-ease 2300 release agent), and Express STD vinylpolysiloxane impression putty. The ability of PlatSil73-25 to create an accurate surface replica was evaluated by creating surface molds of several locations on surface roughness standards representing ISO grade surfaces N 3 , N 5 , N 7 , and N 8 . Overall, the molds were able to accurately reproduce the expected roughness average (R a ) values, but systematically over-estimated the peak-valley maximum roughness (R z ) values. Using a 3D printed sample cell, several locations across the stainless steel spent nuclear fuel canister were sampled to determine the surface roughness. These measurements provided information regarding variability in normal surface roughness across the canister as well as a detailed evaluation on specific surface features (e.g., welds, grind marks, etc.). The results of these measurements can support development of dry storage canister ageing management programs, as surface roughness is an important factor for surface dust deposition and accumulation. This method can be applied more broadly to different surfaces beyond stainless steel to provide rapid, accurate surface replications for analytical evaluation by profilometry.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Enable superior performance of ultra-high loading electrodes through the cost-efficient solvent-free electrode manufacturing technology

This research explores an innovative solvent-free method for fabricating ultra-high loading NMC811 and graphite electrodes (~6mAh∙cm -2 ), showcasing remarkable electrochemical performance enhancements compared to the electrodes prepared by the conventional slurry-casting method. Here, the optimized microstructure with dry-printed (DP) electrodes enhanced electrolyte penetration and minimized lithium-ion diffusion tortuosity resulting in improved rate performance at high current rates. Additionally, this innovative electrode manufacturing approach enables more uniform CEI and SEI formation and growth, which effectively doubles the cycle life of single-layer pouch cells with DP electrodes. Beyond the performance enhancements, this method also offers a notable 29.2 % overall cost advantages, potentially revolutionizing future battery manufacturing. The findings presented in this work underscore the potential of solvent-free manufacturing technology as a high-loading capable and cost-efficient path for advanced battery production.

25 ENERGY STORAGE↗
DOE OSTI2016

Effect of Deep Drying and Torrefaction Temperature on Proximate, Ultimate Composition, and Heating Value of 2-mm Lodgepole Pine (Pinus contorta) Grind

Deep drying and torrefaction is a thermal pretreatment method, where biomass is heated in the temperature range of 150–300°C in an inert or reduced environment. The process parameters like temperature and residence time has a significant impact on proximate, ultimate, and energy properties of the biomass. In the present study, torrrefaction experiments were conducted on 2 mm lodgepole pine grind using a thermogravimetric analyzer. Both deep drying and torrefaction temperature (160–270°C) and time (15–120 min) were selected. Torrefied samples were analyzed for proximate, ultimate and energy properties. Results indicated that moisture content decreased with increases in torrefaction temperature and time, where at 270°C and 120 min, the moisture content was found to be 1.15% (w.b.). Volatile content in the biomass decreased from about 80% to about 45%, and ash content increased from 0.77 to about 1.91% at 270°C and 120 min. The hydrogen, oxygen and sulfur content decreased to 3%, 28.24%, and 0.01 whereas carbon content and higher heating value increased to 68.86% and 23.67 MJ/kg at 270°C and 120 min. H/C and O/C ratio calculated at 270°C and 120 min residence time were about 0.56 and 0.47. This study indicated that higher torrefaction temperatures >230°C and residence time >15 min influenced the proximate, ultimate, and energy properties.

09 BIOMASS FUELS↗
DOE OSTI2016

Aerodynamic Drag Reduction Technologies Testing of Heavy-Duty Vocational Vehicles and a Dry Van Trailer

This study focused on two accepted methods for quantifying the benefit of aerodynamic improvement technologies on vocational vehicles: the coastdown technique, and on-road constant speed fuel economy measurements. Both techniques have their advantages. Coastdown tests are conducted over a wide range in speed and allow the rolling resistance and aerodynamic components of road load force to be separated. This in turn allows for the change in road load and fuel economy to be estimated at any speed, as well as over transient cycles. The on-road fuel economy measurements only supply one lumped result, applicable at the specific test speed, but are a direct measurement of fuel usage and are therefore used in this study as a check on the observed coastdown results. Resulting coefficients were then used to populate a vehicle model and simulate expected annual fuel savings over real-world vocational drive cycles.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Mechanochemical synthesis and intercalation of Ca(II)Fe(III)-layered double hydroxides

A mechanochemical method (grinding the components without added water – dry grinding, followed by further grinding in the presence of minute amount of water or NaOH solution – wet grinding) was used in this work for the preparation and intercalation of CaFe-layered double hydroxides (LDHs). Both the pristine LDHs and the amino acid anion (cystinate and tyrosinate) intercalated varieties were prepared by the two-step grinding procedure in a mixer mill. By systematically changing the conditions of the preparation method, a set of parameters could be determined, which led to the formation of close to phase-pure LDH. The optimisation procedure was also applied for the intercalation processes of the amino acid anions. The resulting materials were structurally characterised by a range of methods (X-ray diffractometry, scanning electron microscopy, energy dispersive analysis, thermogravimetry, X-ray absorption and infra-red spectroscopies). It was proven that this simple mechanochemical procedure was able to produce complex organic–inorganic nanocomposites: LDHs intercalated with amino acid anions. - Graphical abstract: Amino acid anion-Ca(II)Fe(III)-LDHs were successfully prepared by a two-step milling procedure. - Highlights: • Synthesis of pristine and amino acid intercalated CaFe-LDHs by two-step milling. • Identifying the optimum synthesis and intercalation parameters. • Characterisation of the samples with a range of instrumental methods.

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

Cost-Effective Additive Manufacturing of Ambient Pressure-Dried Silica Aerogel

The conventional manufacturing processes for aerogel insulation materials mostly rely on the supercritical drying, which suffers from issues of massive energy consumption, high-cost equipment, and prolonged processing time. Considering the large market demand for the aerogel insulation material in the next decade, a cost-effective and scalable fabrication technique is highly desired. In this paper, a direct ink writing (DIW) method is used to three-dimensionally fabricate the silica aerogel insulation material, followed by room-temperature and ambient pressure drying. Compared with the supercritical drying and freeze-drying techniques, the reported method significantly reduces the fabrication time and costs. The cost-effective DIW technique offers the capability to print complex hollow internal structures, coupled with the porous aerogel structure, it is found to be beneficial for the thermal insulation property. In this work, the addition of fiber to the ink assures the durability of the fabricated product, without sacrificing the thermal insulation performance. The foam ink preparation methods and the printability are demonstrated in this paper, along with the printing of complex three-dimensional geometries. The thermal insulation performance of the printed objects is characterized, and the mechanical properties were also examined. The proposed approach is found to have a 56% reduction in the processing time. The printed silica aerogels exhibit a low thermal conductivity of 0.053 W m –1 K –1 .

36 MATERIALS SCIENCE↗
DOE OSTI2019

Method and apparatus for fabricating ceramic and metal components via additive manufacturing with uniform layered radiation drying

A freeform extrusion fabrication process for producing three-dimensional ceramic, metal and functionally gradient composite objects, including the steps of filling a plurality of paste sources with a respective plurality of aqueous paste compositions, operationally connecting respective syringes containing respective aqueous paste compositions to a mixing chamber, moving a first aqueous paste composition from a first respective paste source into the mixing chamber, moving a second aqueous paste composition from a second respective paste source into the mixing chamber, mixing the first and second aqueous paste compositions to define a first admixture having a first admixture composition, extruding the first admixture onto a surface to define an extruded layer having a first admixture composition, surrounding the sides of the extruded layer with an oil bath, radiatively drying the extruded layer.

Leu, Ming C.↗
DOE OSTI2014

A method for preparation and cleaning of uniformly sized arsenopyrite particles

The oxidative dissolution of sulfide minerals, such as arsenopyrite (FeAsS), is of critical importance in many geochemical systems. A comprehensive understanding of their dissolution rates entails careful preparation of the mineral surface. Measurements of dissolution rates of arsenic from arsenopyrite are dependent on the size and degree of oxidation of its particles, among other factors. In this work, a method was developed for preparation and cleaning of arsenopyrite particles with size range of 150–250 μm. Four different cleaning methods were evaluated for effectiveness based on the removal of oxidized species of iron (Fe), arsenic (As) and sulfur (S) from the surface. The percentage oxidation of the surface was determined using X-ray photoelectron spectroscopy (XPS), and surface stoichiometry was measured using scanning electron microscopy – energy dispersive X-ray spectroscopy (SEM-EDS). Results indicate that sonicating the arsenopyrite particles and then cleaning them with 12N HCl followed by 50% ethanol, and drying in nitrogen was the most effective method. This method was successful in greatly reducing the oxide species of Fe while completely removing oxides of As and S from the arsenopyrite surface. Although sonication and acid cleaning have been widely used for mineral preparation, the method described in this study can significantly reduce grain size heterogeneity as well as surface oxidation, which enables greater control in surface and dissolution experiments.

58 GEOSCIENCES↗