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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

An International Round-Robin Study on Thermoelectric Module Testing and Development of Standard Power Generation Modules

An international round-robin study on thermoelectric power generation modules was conducted with nine participating laboratories. Two types of commercially available bismuth telluride modules, 30 mm × 30 mm and 40 mm × 40 mm, were used. A test protocol was followed with five temperature set points from 50°C to 150°C. Graphite sheets were used as thermal interface materials with test pressure at 100 psi (0.69 MPa). The results showed large lab-to-lab variations and the key source of uncertainty for module efficiency was identified as the heat flux measurement. In the meantime, significant uncertainty was also found in maximum electrical power (P max ) measurements. As a result of the round-robin, a “standard module” with 4 × 4 legs on a 20 mm × 20 mm platform was suggested. A skutterudite module and a half-Heusler module were produced with identical geometry and 4 mm × 4 mm × 8 mm legs. All transport properties to calculate the figure-of-merit, zT, were measured from ambient temperature to 500°C. Module performance was measured by two laboratories. Two finite-element-analysis (FEA)-based models were developed independently to simulate and predict the module performance. In conclusion, the standard modules eliminated significant test uncertainties and are aimed at assisting device design and achieving more accurate performance predictions.

Round-robin↗

This St. Patrick’s Day, take a look at “lucky” Lab artifacts from the Manhattan Project

What luck! Tucked inside J. Robert Oppenheimer’s book Bhagavad-Gita is a four-leaf clover. The famed physicist and first Lab director regularly quoted the Hindu scripture, most notably upon witnessing the Trinity test, which was the successful detonation of the first-ever Los Alamos created atomic bomb. Oppenheimer was said to have recalled the line, “Now I am become Death, the destroyer of worlds.” (The quote, though, has been widely misinterpreted.) The clover is taped to what appears to be a calling card from his spouse Kitty and was found inside his copy of the Bhagavad Gita, which was donated to the Lab’s Bradbury Science Museum by private donors Ben and Sara Beck Svetitsky in early 2020. Kitty Oppenheimer was educated as a botanist and biologist, and accompanied her husband to Los Alamos, along with their two children. The family was here in 1943 through the end of World War II in 1945. The book, with the card found inside, makes up one of two of J. Robert Oppenheimer’s personal effects within the Lab’s collections.

99 GENERAL AND MISCELLANEOUS↗

Roll-to-roll production of catalyst coated membranes for low-temperature electrolyzers

Here we demonstrate a roll-to-roll (R2R) process for direct coating of anode catalyst layers on a polymer electrolyte membrane for low-temperature water electrolysis. To develop this process, we studied catalyst ink formulation, ink-membrane interactions, and coating quality. The catalyst inks were a mixture of iridium oxide (IrO2) and Nafion in a water and alcohol dispersion medium. The type of alcohol (methanol, ethanol, propanols) and water-to-alcohol ratio were varied to determine their influence on membrane swelling, dispersion quality, and coatability. Interactions of the ink dispersion medium with the membrane were characterized using sessile-drop contact-angle measurements. These measurements show that the ratio of water to alcohol has a strong influence on how rapidly the dispersion media is absorbed by the membrane. Rheology of the catalyst inks was measured to understand the microstructure of the catalyst particles in the ink. This analysis found that 1-propanol leads to better dispersion of the IrO2 particles than ethanol. Small-scale coating samples were prepared to understand coating uniformity and formation of irregularities. Subsequently, two water/1-propanol ratios (90:10 and 75:25) were down-selected for large-scale R2R slot die coating. The R2R catalyst-coated membrane (CCM) coating process increased catalyst layer production throughput by over 500x compared to our standard lab-scale spray coating. The CCMs obtained from this process were tested as single-cell membrane electrode assemblies. They exhibited a cell voltage of 1.91 V at a current density of 2 A/cm2, which is comparable to spray-coated CCMs. In conclusion, the work presented here demonstrates a continuous, scalable manufacturing process that eliminates the need for the decal transfer step typically used in CCM production.

42 ENGINEERING↗

Cyber-Secure and Safe Operation of Solar Photovoltaic Power Distribution Systems

Solar photovoltaic (PV)-rich power distribution systems are networked Cyber-Physical Systems (CPS). These are control systems where multiple computing nodes and diverse intelligent agents interact with the physical world in real-time. However, the presence of networked components renders them vulnerable to potential cyber-attacks, cyber-intrusions, and other malicious events. This is because these systems depend on the measurements reported from their heterogeneous sensors. This makes them vulnerable to potential cyber-attacks where malicious agents can compromise the sensors or the communication networks carrying the sensor measurements. This paper proposes a novel methodology for enhancing the cyber-security and cyber-resilient post-attack safe operation of solar PV-rich power distribution systems against potential cyber-attacks through the Dynamic Watermarking (DW), using online system identification. The resiliency of the proposed technique is tested and validated with several attack scenarios on both a lab-scale 3kW grid-connected PV inverter and a Hardware-in-the-Loop (HiL) system. The proposed approach can be applied to other types of power distribution systems to enhance their cyber-secure and cyber-resilient safe operation. This paper thereby contributes to the field of cyber-security of Cyber-Physical Energy Systems (CPES).

Kim, Jaewon↗

DARHT : Enduring Lessons from a Technical Project in a National Laboratory Context [Slides]

The Dual-Axis Radiographic Hydrodynamic Test (DARHT) facility at Los Alamos National Laboratory (LANL) is the world’s first flash x-ray facility able to take multiple high-resolution radiographs of the interior features of fast-moving dense objects during a single experiment. DARHT’s radiography and complimentary diagnostics makes it an important diagnostic tool in support of the US Department of Energy’s (DOE)/National Nuclear Security Administration (NNSA)’s stewardship of the US nuclear deterrent. The project to construct DARHT ran from 1988 through 2003. Initial Operating Capability along a single axis began in 1999. A technical issue delayed Critical Decision 4 for the full dual-axis capability until 2008. DARHT was characterized by several directed changes resulting from an environmental impact study, changes to the global security context resulting from the end of underground nuclear testing, and rapid evolution of applicable technology. Conventional building and lab-space construction were part of the project, but the project was dominated by Special Facility Equipment that, together with the mission to support the nuclear weapons program, required the project to be completed by national laboratories. Although the project pre-dated implementation of DOE Order 413.3, several important lessons for national laboratory projects remain applicable today and will be discussed here, including projects appropriate for the national laboratory environment, scope stability, risk acceptance and mitigation, communication, and collaboration. Finally, considerations for DOE contractor project managers are offered based upon the DARHT experience.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems

The large thermal gradients and high subsurface temperatures of the western region of the U.S. hold great potential for the implementation of enhanced geothermal systems (EGS). The development of these potential EGS resources requires stimulation of the reservoir to enhance permeability and it has been widely reported that a substantial amount of water will be required should conventional hydraulic stimulation be used. This presents a huge challenge and a high risk to the geothermal development because the water stress1 in these areas is already high or extremely high. The use of foam, a gas/liquid mixture predominantly composed of gas, in fracturing is considered and explored in this project as a potential approach to address water concerns with hydraulic stimulation in the development of EGS. This project, led by Oak Ridge National Laboratory (ORNL) in collaboration with Temple University, was awarded in an open lab call in 2018, and was part of the DOE GTO waterless stimulation initiative. The goal of the project was to demonstrate the feasibility of foam fracturing for EGS development through two primary tasks: Task 1: Laboratory study of the effectiveness of foam fracturing for representative geological materials, including cyclic pressurization using foam (led by ORNL) and Task 2: High temperature foam material selection and characterization (led by Temple University). In FY19, ORNL finished the critical review on serval issues associated with foam fracturing and the implementation of the proposed tasks in a lab study (Wang, et al., 2019), and completed the foam fracturing testing using cement as a model material (Wang, et al, 2020a). The work at ORNL was geared up to develop a brand-new foam testing system in FY20. The purchase of main components for the new system was finished in the first half of the FY20. The assembly of the foam testing system and foam fracturing testing were completed in the second half of the FY20 (Wang, et al., 2021a). Task 1 required the development of a test system which can be used to perform hydraulic fracturing of geological specimens with both water and foamed liquids at pressure up to 6,000 psi (41.4 MPa). The system possesses several capabilities that conventional injection systems lack for hydraulic fracturing. In addition to its ability to generate foam with controlled quality, it is capable of cycling pressure levels between specified values up to frequencies of 50 Hz. The latter capability was developed to evaluate the hypothesis that cyclic loading of samples would produce enhanced fracturing. The system consists of two sections: one for foam generation and another for foam injection. The foam is generated through separate control and pressurization of liquid and gas phases with controlled flow rates. The injection section is equipped with a low-flow Coriolis flow that monitors the density of foam to ensure the injection is in the range of target foam quality2. Experimental results of foam fracturing are reported for cylindrical granite specimens using water and aqueous N2 foam as the fracturing fluids. All experiments were performed for unconfined conditions. The effects of injection mode (i.e., monotonic vs cyclic pressurization) on breakdown pressure and failure response sample were investigated using water alone as a fracturing fluid and foams with a range of compositions. It was found that in the case of monotonic injection, the breakdown pressure of granite specimens tended to be slightly higher when fracturing with foam. Additionally, with a foam quality of 90%, the water use can be reduced by 50 to 84%, depending on hole size. On the other hand, it was observed that the breakdown pressure can be brought down to 70% of the monotonic breakdown pressure by using low cycle fatigue. Finally, discussions are presented regarding injectivity and water use reduction.

15 GEOTHERMAL ENERGY↗

LLNL Explosives Anisotropy Research

Lawrence Livermore National Laboratory scientists and engineers led a multi-institutional team in executing a series of high explosives tests that successfully demonstrated fundamental principles of anisotropy, a possible enabler for improved weapon and munition safety. Working under snowy and frigid conditions on Idaho’s Snake River Plain, a 13-member team from LLNL carried out 52 explosives shots over four days in mid-November at the Idaho National Laboratory’s (INL) National Security Test Range (NSTR) to complete the study. The broader anisotropy (ANISO) team included high explosives handlers and volunteers from INL, Los Alamos National Laboratory, Marine Raiders from the Marine Special Operations Command and members of the U.S. Special Operations Command. The purpose of the study was to explore theoretical methods of creating anisotropic explosives — explosives that perform differently depending on the direction the detonation wave moves through the explosive — by engineering certain physical features in the charges and obtaining basic data from testing. The work is part of an overall effort by the Lab to develop anisotropic explosives that could be used in munitions to reduce the severity and lethality of an unintended detonation without sacrificing performance. The data gathered from the study will be used to design and construct follow-on experiments at LLNL’s High Explosives Applications Facility (HEAF) and validate computer models for future anisotropic assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Optimal Control of an Oscillating Surge Wave Energy Converter

During this project, we experimentally investigated the hydrodynamics and performance of a laboratory-scale oscillating surge wave energy converter (OSWEC).We looked at how flap buoyancy and driveline losses (primarily in the form of stiction) affected the dynamics and performance of the device. In addition, we assessed the influence of flap profile (rounded vs. square edges) on OSWEC hydrodynamics. Through this, we were able to develop a deeper understanding of OSWEC performance and provide guidance on strategies to counteract artifacts that may be present in laboratory models, but are absent in field-scale devices. To do this, we tested a laboratory-scale OSWEC in the Sea Wave Environmental Lab (SWEL) wave tank at the National Renewable Energy Laboratory (NREL). We ran several types of experiments to investigate the hydrodynamics and performance of the device. Overall, we achieved the overall goal of experimentally investigating the hydrodynamics and performance of this device. We discovered important and unexpected trends in performance, and collected time-resolved data to help us further investigate the underlying hydrodynamics responsible for these trends. In addition, we are currently using the time-resolved data from these experiments to build data-driven models of the dynamics, which can in turn be used to inform data-driven model predictive control of this device and address this objective in the future.

16 TIDAL AND WAVE POWER↗

Synthetic Digital Environments for Training Robots on Earth & Beyond [Poster]

Creating physical replicas of real-world environments to train robots for challenging outdoor tasks, whether constructing energy infrastructure like solar farms on Earth or on the Moon and Mars, is prohibitively expensive. This project will prototype a high-fidelity digital twin framework using NVIDIA IsaacSim to create realistic digital representations of robotic systems and their operating conditions, including varied terrains and environmental factors, allowing robots to learn and adapt in a faster, safer, and more affordable way to tackle unpredictable challenges in terrestrial and extraterrestrial applications. The Robotic Space Exploration (RoSE) Lab at Colorado School of Mines focused on the development and testing of synthetic digital twins to explore multi-physics interactions between robots and unstructured environments, with emphasis on lunar conditions such as deformable regolith, reduced gravity, and terrain-robot contact dynamics. The Industrialized Construction Innovation (ICI) team at National laboratory of the Rockies (NLR), simulated robotic apparatus and construction workflows using synthetic digital twins to inform real-world deployment, targeting application-driven use cases such as robotic construction of a scaled prototype of a photovoltaic energy infrastructure. Joint efforts between RoSE and ICI are continuing to explore how environment-scale multi-physics modeling and application-level robotic system simulation could be integrated to support robotic construction of energy infrastructure in highly unstructured environments, including scenarios relevant to the Lunar South Pole.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Investigation of Flux Spreading in a Light-Trapping, Planar-Cavity Receiver for Enclosed Solar Particle Heating

Concentrating solar thermal power (CSP) technology development has recently focused on increasing the operating temperatures to accommodate high efficiency power cycles and thermochemical processes. Inert solid particles as heat transfer media enable solar receivers to operate above 700 degrees Celsius resulting in increased system thermal efficiency compared to the conventional molten salt based CSP system. An open-cavity falling-particle solar receiver that can efficiently heat particles by direct heating from concentrated solar radiation faces challenges with large particle losses from wind and unable to support thermochemical reactions. A light-trapping, planar cavity reiver (LTPCR) where particles are indirectly heated can significantly minimize the particle losses during the operation, support thermochemical reactions, and offer scalability potential. The LTPCR features an array of vertical planar receiver/absorber panels arranged within a cavity configuration. Concentrated solar radiation from heliostats is focused onto the receiver walls, where heat is indirectly transferred to solid particles flowing inside the receiver channels. Heat transfer occurs through direct contact between the receiver panel walls and particles, and can be enhanced by fluidizing particles with air. This fluidization increases particle-wall contact and extends particle residence time, maximizing heat transfer efficiency. The unique vertical planar receiver structure originated from a near-blackbody tubular light absorber, effectively distributing the incoming solar beam spread across the panel walls and trapping light. This flux spreading effect, driven by cosine projection, converts high incident solar flux into a lower, more uniform heat flux on the panel walls. This redistribution enhances heat transfer efficiency between particle-wall or reaction gases-wall, while preventing localized overheating of the receiver panel. Indirect planar cavity solar receivers completely separate solid particles from the ambient environment that can greatly reduce the thermal losses in heated particles resulting in high efficiency at high temperatures above 700 degrees Celsius. This design ensures no particle losses to the environment during the operation while open-cavity designs can experience significant particle losses from wind. An experimental investigation was conducted to observe flux spreading on the receiver panel wall. A lab-scale prototype planar receiver, fabricated using Haynes 230 alloy, was tested under direct concentrated solar radiation using the high-flux solar furnace (HFSF) facility at NREL. The experiment was performed under normal peak radiative heat fluxes ranging from 800 to 1900 kW/m2. A temperature distribution on the panel wall was measured using a thermal imaging camera (FLIR A 6600). To prevent overheating at the receiver front tip, prism-shaped heat shields (Zircar UNIFROM C1) were placed in front of the receiver, and their influence on flux spreading was also studied. Absorbed flux distribution on the panel wall was modeled using SolTrace. The total solar power and flux distributions delivered from HFSF were determined based on the heliostat mirror optical properties, direct normal irradiance (DNI) on the on-sun testing days, peak flux measurement during the on-sun testing, and shutter/attenuator settings Due to the large incident angles of the solar beam on the panel wall, the angular optical properties of Haynes 230 alloy and Zircar heat shields were incorporated into the model. This flux distribution model was then integrated into a computational fluid dynamics (CFD) simulation to predict the receiver panel wall temperature, which was compared with the experimental measurements. Both prediction and measurements identified a temperature hotspot at the backside of the panel, indicating that the incident solar beam can fully reach to the rear of the receiver. The heat shields positioned at the front of the receiver effectively reduced the excessive temperature rise at the receiver front tip. Overall, the temperature was well distributed over the panel wall, with a minor hotspot at the back of the receiver. The model slightly overpredicted the temperature, possibly due to discrepancies in optical properties of the panel and an underprediction of thermal loss in the receiver. The advancement of the particle LTPCR offers a viable alternative to open-cavity receivers by addressing particle loss issues. Additionally, it presents a pathway for enabling solar thermochemical processes, extending CSP technology beyond power generation to fuel and chemical production.

14 SOLAR ENERGY↗

Sierra/SD – Verification Test Manual – 5.22

Verification and validation (V&V) of scientific computing programs are important at Sandia National Labs due to the expanding role of computational simulation in managing the United States nuclear stockpile. The complexities of structural response calculations used to analyze physical problems, the varieties of codes applied to the calculations, and the importance of accurate predictions when assessing field conditions demand confidence in the consistency and accuracy of computer codes. Confidence in the accuracy of the predictions arising from computer simulations must ultimately be gained through verification and validation. The Sierra salinas structural dynamics analysis code, Sierra/SD, is used at the DOE Laboratories, and in several DOD projects. The roles of Sierra/SD in the qualification of weapon systems and components for normal and hostile environments throughout the Stockpile-to-Target Sequence include to, • Redesign weapon components. • Certify weapon components and systems for target environments such as hypersonic vehicles. • Certify that components will survive the thermal mechanical shock loads associated with hostile environments. • Evaluate current stockpile issues, including issues associated with uncertainty quantification. • Address many other problems that are encountered in stockpile management. The Sierra/SD verification plan is described, and an evolving set of key verification tests are described in detail. The verification tests ensure the correctness of the mathematics and numerical algorithms associated with functionality describing engineering phenomena. Development is in accordance with a set of tailored Software Quality Engineering (SQE) practices. SQE practices guide the overall verification and validation effort.

97 MATHEMATICS AND COMPUTING↗

Laser Measurements and Modeling of Shock Tunnel Freestream Velocity and Multispecies Thermal Nonequilibrium

Coherent anti-Stokes Raman scattering (CARS) and nitric oxide molecular tagging velocimetry (NO-MTV) were used to characterize the freestream in Sandia’s Hypersonic Shock Tunnel (HST) using a burst-mode laser operated at 100 kHz. Experiments were performed at nominal freestream velocities of 3 and 4 km/s using both air and N 2 test gas. The CARS diagnostic provides nonequilibrium characterization of the flow by measuring vibrational and rotational temperatures of N 2 and O 2 , which are compared to NO temperatures from separate laser absorption experiments. Simultaneous, collinear freestream velocities were measured using NO MTV along with pitot pressure measurements. Furthermore, this extensive freestream dataset is compared to nonequilibrium CFD that is capable of modeling species-specific, vibrational temperatures throughout the nozzle expansion. Significant nonequilibrium between vibrational and rotational temperatures was measured at each flow condition. N 2 exhibits the most nonequilibrium, followed by O 2 and NO. The CFD model captures this trend, although it consistently overpredicts N 2 and O 2 vibrational temperatures. At 3 km/s, the modeled NO nonequilibrium is underpredicted, whereas it is overpredicted at 4 km/s. Good agreement is seen between CFD and the velocity and rotational temperature measurements. Experiments with water added to the test gas yielded no discernable difference in vibrational relaxation.

Aerodynamics↗

Cross-Section Comparison for Pu-238 Production in the Advanced Test Reactor at Idaho National Laboratory

Qualification of Advanced Test Reactor (ATR) positions for Pu-238 production has been ongoing at Idaho National Laboratory (INL). The ATR qualifications have stretched over multiple years during which new techniques have been developed and made available for ATR experiment neutronic analysis. As part of the transition to newer codes, new cross-section libraries have been evaluated for use in the Pu-238 production experiment analysis. A comparative study was done using the MCNP ORGIEN Activation Analysis (MOAA) tool between ENDF/B-VII.0 and ENDF/B-VIII.0 cross sections to capture the impact of the change in cross-sections on the analysis needed to qualify Pu-238 production targets. All comparisons were done assuming the ATR GEN-I targets were located in the south flux trap of the ATR. Finally, an overview of how this qualification and potential irradiation fits into Pu-238 is discussed.

07 ISOTOPE AND RADIATION SOURCES↗

A VXS [VITA41] Trigger Processor for the 12GEV Experimental Programs at Jefferson Lab

The VXS_Trigger_Processor [VTP] was developed and commissioned for CLAS12 in the fall of 2016. This board is a VITA41 switch card and it collects data from a variety of front-end TDC and Flash ADC modules. The VTP has since been used in several experiments at Jefferson Lab serving as the L1 trigger module for a variety of detector types, such as stacked calorimeters, strip calorimeters, time-of-flight, Cerenkov, hodoscopes, drift chambers, and silicon strips. Trigger algorithms implemented include cluster finding (1D, 2D), drift chamber segment and road finding, geometry matching between various detectors, particle counting, and general global trigger bit processing. The VTP is also capable of reading out each front-end crate with up to 40Gbps Ethernet which is an enormous increase compared to the currently used 200MB/s VME bus. Recent progress has been made to show that a firmware and software upgrade can enable existing Jefferson Lab front-end crates to operate in a streaming DAQ mode. In February 2020, tests will be performed on a full calorimeter and matched hodoscope which are components of the CLAS12 Forward Tagger detector system with beam in Hall B. This paper details the hardware performance, triggered, and streaming applications that have been implemented using the VTP for several experiments at Jefferson Lab.

ABBOTT, David↗

Understanding TRISO Coated Particle Neutron Irradiation Behavior:Evolution of Advanced Micro Analysis and Electron Microscopy Approaches

Objectives and motivation• Provide data for fuel qualification in support of reactor licensing• Establish a domestic commercial TRISO fuel fabrication capability Approach • Focus is on developing and testing UCO TRISO fuel –Develop fuel fabrication and QC measurement methods, first at lab scale and then at industrial scale –Perform irradiation testingover a range of conditions (burnup, temperature, fast neutron fluence) –Perform post-irradiation examination and safety testingto demonstrate and understand performance during irradiation and during accident conditions –Develop fuel performance modelsto better predict fuel behavior –Perform fission product transport experiments to improve understanding and refine models of fission product transport

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

National Marine Renewable Energy Center Upgrades - LUPA

The data provided is part of a power take off damping optimization study. The power take off damping coefficient was swept from 0 to approximately 7000 N/m/s during a single regular wave test with a real time control of the motor/generator. The generated power from the LUPA (Lab Upgrade Point Absorber) wave energy converter is reported by the motor drive in watts. The csv files in this submission are the corresponding raw time series outputs for each mode of operation of LUPA (one body heave only, two body heave only, and two body six degrees of freedom). Data comes from testing in the Large WaveFlume (LWF) at the O.H. Hinsdale Wave Research Laboratory in Corvallis, OR.

16 TIDAL AND WAVE POWER↗

Cooling Performance Testing of Attaway's Negative Pressure CDU

Attaway is a recently installed High-Performance Computing (HPC) machine at Sandia National Labs that is 70% water-cooled and 30% air-cooled. This machine, supplied by Penguin Computing, uses a novel new cooling system from Chilldyne that operates in a vacuum, preventing water leaks. If water-cooling is to fail, fans inside of each node will ramp up to do 100% of the cooling on Attaway. Various tests were completed on Attaway to determine the robustness of its cooling system as well as its ability to respond to sudden changes in states. These changes include an immediate change from an idle compute load to full load (Linpack) as well as running Linpack without any water cooling from Attaway's CDUs. It was discovered that Attaway could respond to sudden compute load changes very well, never throttling any nodes. When Linpack was run without water cooling, the system was able to operate for a short time before throttling happened.

42 ENGINEERING↗