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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Innovative accident tolerant fuel concept enabled through direct manufacturing technology

Nuclear energy is one of the largest sources of carbon-free electricity in the world. Some countries are looking at new ways to support and revitalize the nuclear sector since the Fukushima disaster. The accident tolerant fuel program is geared toward improving the safety of nuclear energy by investigating materials that can replace or modify the current uranium-dioxide nuclear fuel and zirconium-based cladding. This research program is being supported by all major nuclear countries since 2011. The practical limitations on allowable uranium enrichment has taken the focus away from the most promising fuels with high radioactivity retention such as tristructural isotropic particle fuel. To overcome such enrichment limitation, a new fuel concept is proposed using advanced ceramic direct manufacturing with laser-induced chemical vapor deposition. The fuel-as-fiber concept is an accident-tolerant fuel design that features high thermal conductivity, strong capability of radioactivity retention and most importantly requires reasonable enrichment levels with uranium nitride as the fuel. In this work, the initial fabrication of uranium-based fuel with laser-induced chemical vapor deposition technology is demonstrated. Then an advanced multi-physics guided modeling approach based on finite element analysis codes and informed by the manufacturing capabilities is developed to accelerate the advancement of fuel-as-fiber concept for use in current light-water reactor technology. The detailed thermomechanical analysis showed promising results for viability of the innovative fuel-as-fiber concept. The predicted stresses in the fuel structural materials were similar to the case of tristructural isotropic particle fuel experience base that has shown excellent reliability in retention of fuel radioactivity at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1996

Integrated Airframe Technology: The Future of Advanced Composites

The challenge for advanced composites in integrated airframe technology is that: airframes must provide ever increasing performance at an affordable cost; reduce costs as compared to current airframe technology; and integration of design and manufacturing. The trend in technology is that a gap exists between the potential of advanced composites and our ability to effectively utilize them (cost/weight).

Taggart, David F.↗
DOE OSTI2020

Co-Extrusion (CoEx) for Cost Reduction of Advanced High-Energy-and-Power Battery Electrode Manufacturing

Co-Extrusion (CoEx) is a deposition technology developed at PARC that uses engineered fluidic channels to cause multiple streams of dissimilar fluids to impart shape to one another. Here, we describe the use of CoEx to produce structured cathode electrode films to improve electrochemical performance of thick electrode films. CoEx enables us to create structured electrode films that have periodic regions of enhanced ionic conductivity, enabling higher utilization of thicker cathode films at high discharge rates. While increasing electrode thickness is a known method for increasing energy density of battery electrodes, this increase in energy density typically also results in reduced power density. This project, a collaboration between the Palo Alto Research Center, Oak Ridge National Laboratories, and Ford Motor Company, seeks to first validate the benefits of CoEx at the coin cell level, before performing the necessary R&D effort to scale production up to large (10+ Ah) pouch cells that will show increased energy density without a reduction in power density. We used conventional battery materials (commercially available NMC, PVDF, carbon black, and graphite) to produce structured electrodes via CoEx and compared them to thick and thin conventionally produced (unstructured) battery electrodes. CoEx electrodes show improved high rate performance compared to unstructured electrodes, resulting in higher energy density pouch cells compared to the baseline electrode of 7 and 11% in volumetric and gravimetric energy density, respectively. These electrodes also showed substantially improved electrochemical performance at high discharge rates compared to thick conventional electrodes.

25 ENERGY STORAGE↗
DOE OSTI2021

Embedding Sensors in 3D Printed Metal Structures

The Transformational Challenge Reactor (TCR) program is leveraging recent advances in modeling and simulation, materials, and additive manufacturing (AM) technologies to design a modern nuclear reactor. Some of the main TCR technologies include in situ monitoring and the integration of sensors during the manufacturing of quality-significant nuclear reactor components. This report describes the general procedure and process optimization for embedding sensors within generic stainless steel 316 (SS316) components using laser powder bed fusion (LPBF). A more detailed, quality-significant test plan and supporting procedures are available upon request (ORNL/TM-2021/2127). LPBF involves the use of a scanning laser to selectively melt regions of a powder bed, additively building a part layer by layer. This report describes the LPBF processing technique and discusses the effects of LPBF processing parameters on the success of the sensor embedding process. Experiments used machined cavities in the form of channels in an SS316 base for the sensors to lay in while material is additively built over the top, thereby embedding them in an SS316 matrix. A preliminary investigation involved using empty SS316 sheaths as surrogates to explore the effects of various LPBF processing parameters and the dimensional requirements of the machined channels. Microstructural investigations showed that a smaller channel width/depth combination closer to the sensor’s diameter was best for the embedding process. After the desired parameters were selected, Type-K thermocouples were embedded and evaluated post-embedding using nondestructive thermal testing, as well as destructive sectioning and microscopy. Post-build characterization showed that the thermocouples were well-bonded to the SS316 matrix and were fully functional after embedding. During thermal testing to temperatures up to 500 °C, the embedded thermocouples read consistently with one another and deviated only slightly from the readings of a nonembedded thermocouple located within the furnace. This slight discrepancy was most likely due to differences in the thermal time constants for a nonembedded thermocouple vs. a thermocouple embedded in a solid SS316 block. The results presented in this report will serve as the foundation for future work that will focus on embedding sensors in relevant TCR reactor components and eventually testing those components under neutron irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2

As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.

17 WIND ENERGY↗
DOE OSTI2024

Isolated Single Metal Atoms Supported on Silica for One Step Non-Oxidative Methane Upgrading to Hydrogen and Value-Added Hydrocarbons

Natural gas in the United States offers substantial economic opportunities due to its abundance but its transportation is challenging because its primary component, methane (CH 4 ), does not liquefy at ambient temperature and typical pressures. As a result, a significant portion of natural gas is either used for heat, flared in remote locations, or remains unutilized, presenting a lost economic opportunity and an environmental harm. Converting natural gas to larger hydrocarbons in an economically competitive manner would enable transportation of products and further boost the economy and reduce environmental footprint. Our research goal is to enable efficient non-oxidative methane conversion (NMC) via catalyst innovation to convert CH 4 in one-step to olefins and aromatics and hydrogen (H 2 ) co-product. The catalysts are made of supported single metal atoms and operated at medium-high temperatures. The single metal atoms achieve methane activation by heterogeneous surface dehydrogenation to generate a hydrocarbon pool and importantly limit coke formation. The integration of novel single atom catalysts in a short contact time microreactor enable unprecedented NMC performance that could lead to economically-feasible, distributed natural gas upgrading by advanced manufacturing and process intensification. Our innovated catalyst and reactor technology promise to tap into previously uneconomic natural gas resources, such as stranded, vented, and flared methane.

03 NATURAL GAS↗
NASA NTRS1990

Applying CLIPS to control of molecular beam epitaxy processing

A key element of U.S. industrial competitiveness in the 1990's will be the exploitation of advanced technologies which involve low-volume, high-profit manufacturing. The demands of such manufacture limit participation to a few major entities in the U.S. and elsewhere, and offset the lower manufacturing costs of other countries which have, for example, captured much of the consumer electronics market. One such technology is thin-film epitaxy, a technology which encompasses several techniques such as Molecular Beam Epitaxy (MBE), Chemical Beam Epitaxy (CBE), and Vapor-Phase Epitaxy (VPE). Molecular Beam Epitaxy (MBE) is a technology for creating a variety of electronic and electro-optical materials. Compared to standard microelectronic production techniques (including gaseous diffusion, ion implantation, and chemical vapor deposition), MBE is much more exact, though much slower. Although newer than the standard technologies, MBE is the technology of choice for fabrication of ultraprecise materials for cutting-edge microelectronic devices and for research into the properties of new materials.

Rabeau, Arthur A.↗
NASA NTRS1994

Use of prismatic films to control light distribution

Piping light for illumination purposes is a concept which has been around for a long time. In fact, it was the subject of an 1881 United States patent which proposed the use of mirrors inside a tube to reflect light from wall to wall down the tube. The use of conventional mirrors for this purpose, however, has not worked because mirrors do not reflect well enough. On the other hand, optical fibers composed of certain glasses or plastics are known to transport light much more efficiently. The light that enters is reflected back and forth within the walls of the fiber until it reaches the other end. This is possible by means of a principle known as 'total internal reflection'. No light escapes through the walls and very little is absorbed in the bulk of the fiber. However, while optical fibers are very efficient in transporting light, they are impractical for transporting large quantities of light. Lorne Whitehead, as a student at the University of British Columbia, recognized that prismatic materials could be used to create a 'prism light guide', a hollow structure that can efficiently transport large quantities of light. This invention is a pipe whose transparent walls are formed on the outside into precise prismatic facets. The facets are efficient total internal reflection mirrors which prevent light travelling down the guide from escaping. Very little light is absorbed by the pipe because light travels primarily in the air space within the hollow guide. And, because the guide is hollow, weight and cost factors are much more favorable than would be the case with very large solid fibers. Recent advances in precision micromachining, polymer processing, and certain other manufacturing technologies have made the development of OLF (Optical Lighting Film) possible. The process is referred to as 'microreplication' and has been found to have broad applicability in a number of diverse product areas.

Kneipp, K. G.↗
NASA NTRS2009

One NASA PEM qualification standard : comparison of JPL and GSFC standards

Although use of Plastic Encapsulated Microelectronics (PEMs) in space applications is discouraged, their use is mandatory for selected applications involving the need for advanced technology and small packages. Various space systems designers and manufacturers have developed methods to qualify and screen PEMs. In general, each procedure is different. The purpose of this fiscal year’s investigation is to initiate a process to coordinate the efforts at various NASA centers to eventually develop a One NASA method. Part of this activity includes sharing of test data and PEM qualification methodologies. Various experts in the NASA community were identified and contacted to support this effort. We were successful in finding such experts at GSFC, APL and the Constellation office (Orion and Ares). All these experts provided typical qualification program plans. Since funding was severely restricted, it was decided to concentrate on coordination activity with GSFC. GSFC is planning a new version of IEEE-INST-002 section applying to PEMs. The GSFC expert (Dr. Alexander Teverovsky) provided a detailed assessment of the differences between the planned new version of IEEE-INST-002 and the JPL-D-19426 (JPL guideline) as well as a summary rationale for the decisions within the IEEE-INST-002. It should be noted that GSFC’s assessment of IEEE-INST-002 in the area of PEMs is not finalized. JPL is also considering changes in PEM qualification methodologies based on test data from recent qualification testing for their newer Projects (MSL, Grail, Juno). A spreadsheet delineating the differences between the JPL standard and the GSFC standard is presented.

Cooper, Mark↗
NASA NTRSDate not supplied

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗
DOE OSTI2020

Investigating Porous Media for Relief Printing Using Micro-Architected Materials

Advances in printed electronics are predicated on the integration of sophisticated printing technologies with functional materials. Although scalable manufacturing methods, such as letterpress and flexographic printing, have significant history in graphic arts printing, functional applications require sophisticated control and understanding of nanoscale transfer of fluid inks. In this paper, a versatile platform is introduced to study and engineer printing forms, exploiting a microscale additive manufacturing process to design micro-architected materials with controllable porosity and deformation. Building on this technology, controlled ink transfer for submicron functional films is demonstrated. The design freedom and high-resolution 3D control afforded by this method provide a rich framework for studying mechanics of fluid transfer for advanced manufacturing processes.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Composite structural materials

The use of filamentary composite materials in the design and construction of primary aircraft structures is considered with emphasis on efforts to develop advanced technology in the areas of physical properties, structural concepts and analysis, manufacturing, and reliability and life prediction. The redesign of a main spar/rib region on the Boeing 727 elevator near its actuator attachment point is discussed. A composite fabrication and test facility is described as well as the use of minicomputers for computer aided design. Other topics covered include (1) advanced structural analysis methids for composites; (2) ultrasonic nondestructive testing of composite structures; (3) optimum combination of hardeners in the cure of epoxy; (4) fatigue in composite materials; (5) resin matrix characterization and properties; (6) postbuckling analysis of curved laminate composite panels; and (7) acoustic emission testing of composite tensile specimens.

Ansell, G. S.↗
NASA NTRS2016

Composites for Exploration Upper Stage

The Composites for Exploration Upper Stage (CEUS) was a 3-year, level III project within the Technology Demonstration Missions program of the NASA Space Technology Mission Directorate. Studies have shown that composites provide important programmatic enhancements, including reduced weight to increase capability and accelerated expansion of exploration and science mission objectives. The CEUS project was focused on technologies that best advanced innovation, infusion, and broad applications for the inclusion of composites on future large human-rated launch vehicles and spacecraft. The benefits included near- and far-term opportunities for infusion (NASA, industry/commercial, Department of Defense), demonstrated critical technologies and technically implementable evolvable innovations, and sustained Agency experience. The initial scope of the project was to advance technologies for large composite structures applicable to the Space Launch System (SLS) Exploration Upper Stage (EUS) by focusing on the affordability and technical performance of the EUS forward and aft skirts. The project was tasked to develop and demonstrate critical composite technologies with a focus on full-scale materials, design, manufacturing, and test using NASA in-house capabilities. This would have demonstrated a major advancement in confidence and matured the large-scale composite technology to a Technology Readiness Level 6. This project would, therefore, have bridged the gap for providing composite application to SLS upgrades, enabling future exploration missions.

composites↗
DOE OSTI2022

Bi-metallic Nanoparticle Synthesis for Advanced Manufactured Melt Wires

Science Undergraduate Laboratory Internship (SULI) Program Report: Additive manufacturing (AM) based on direct-write technologies has emerged as the predominant method for the fabrication of passive sensors for the harsh operating environments seen in a nuclear reactor. Through the modification of previous methods, Idaho National Laboratory and Villanova University have improved the synthesis process for AM feedstock, which will allow for the improvement of advanced nuclear sensors and instrumentation. A major part of this work includes the synthesis process of relevant AM compatible feedstock to support the development, fabrication, and testing of AM sensors for peak temperature detection. For this report, bismuth, bismuth/platinum, tin, tin/silver, tin/zinc, indium, and indium/silver bi-metallic nanoparticles were synthesized using the polyol method, which will enhance temperature sensitivity and allow for miniaturization. To characterize the synthesized nanoparticles, we used x-ray fluorescence to evaluate the elemental composition of the nanoparticles and differential scanning calorimetry and thermogravimetric analysis to determine the melting point and mass loss of the samples. Results show that bi-metallic nanoparticles are a viable option for the fabrication of high-resolution AM melt wires. The temperature sensitivity can be brought to within 5°C and melt wires can be fabricated that are in the micrometer scale. This will expand the range of irradiation experiments melt wires can be used for and the measured temperature will be significantly more accurate.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Transforming Energy Through Computational Excellence: High-Performance Computing for Energy Innovation

The challenges associated with energy efficiency of manufacturing and advanced materials often cannot be addressed through experimentation alone, whether because of scale, complexity, or practicality. High-performance computing (HPC) enables fast tackling of these challenges in the manufacturing sector - vital to achieving net-zero carbon emissions by 2050. The National Renewable Energy Laboratory (NREL) and industry partners leverage HPC to apply advanced modeling, simulation, and data analysis to improve manufacturing efficiency, explore new materials for energy applications, and develop technologies to manage carbon across the life cycle. From improving additive manufacturing processes to increasing the energy efficiency of jet-engine components, advanced computing can help manage emissions produced by manufacturing in a wide variety of ways.

advanced materials↗
DOE OSTI2020

Accomplishments and Mid-Year Performance Report: Wind Energy Program Fiscal Year 2020

Through transformative science and innovation, the U.S. Department of Energy's (DOE's) National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory's (NREL's) Flatirons Campus helps lead the way to a sustainable energy future that powers America with significant levels of reliable, low-cost, and accessible wind energy. Since 1976, NREL has provided an ideal environment for the research and development (R&D) of advanced energy technologies through: Wind energy resource assessments, World-class research facilities, High-performance computing and modeling, Data and technology analysis, Manufacturing breakthroughs, Environmental analysis and wildlife conservation efforts, Education and training programs for a future workforce. These activities enable the innovations needed to advance U.S. wind systems, address market and deployment barriers, and drive down the cost of wind energy with more efficient, more reliable, and more predictable wind energy systems. This report provides an overview of the achievements NREL delivered on behalf of DOE's Wind Energy Technologies Office (WETO) and other partners during the first and second quarters of Fiscal Year (FY) 2020.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
NASA NTRS1992

Solar concentrator technology development for space based applications, volume 2

Thermoelectric conversion using a radio-isotope heat source has been used where outer planetary space craft are too far away for absorbing significant solar energy. Solar dynamic power (SDP) conversion is one technology that offers advantages for applications within the inner planet region. Since SDP conversion efficiency can be 2 to 3 times higher than photovoltaic, the collecting surfaces are much reduced in area and therefore lighter. This becomes an advantage in allocating more weight to launched payloads. A second advantage results for low earth orbit applications. The reduced area results in lower drag forces on the spacecraft and requires less reboost propellant to maintain orbit. A third advantage occurs because of the sun-to-shade cycling while in earth orbit. Photovoltaic systems require batteries to store energy for use when in the shade, and battery life for periods of 10 to 15 years is not presently achievable. For these reasons the Solar Dynamics and Thermal Systems Branch at NASA LeRC has funded work in developing SDP systems. The generic SDP system uses a large parabolic solar concentrator to focus solar energy onto a power conversion device. The concentrators are large areas and must therefore be efficient and have low specific weights. Yet these surfaces must be precise and capable of being stowed in a launch vehicle and then deployed and sometimes unfurled in space. There are significant technical challenges in engineering such structures, and considerable investigation has been made to date. This is the second of two volumes reporting on the research done by the Advanced Manufacturing Center at Cleveland State University to assist NASA LeRC in evaluating this technology. This volume includes the appendices of selected data sets, drawings, and procedures. The objective of the grant was to restore the solar concentrator development technology of the 1960s while improving it with advances that have occurred since then. This report summarizes the work done from January 1989 through December 1991.

Pintz, A.↗
DOE OSTI2024

Advanced Manufacturing and Materials for Hydropower Strategy

Advanced manufacturing and materials (AMM) are revolutionizing how the energy sector is built, and the hydropower industry stands to benefit greatly from these new opportunities. The mission of the U.S. Department of Energy’s (DOE) Water Power Technologies Office (WPTO) is to enable research, development, and testing of new technologies to advance marine energy as well as next-generation hydropower and pumped storage systems for a flexible and reliable grid. This strategic plan outlines how WPTO can support AMM technologies for hydropower and pumped storage applications.

13 HYDRO ENERGY↗