Search NASA⌕ Search

SEARCH · Search NASA

Results for “Advanced Manufacturing Technologies”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Intelligent Manufacturing for Extreme Environments Conference Proceedings

The Intelligent Manufacturing for Extreme Environments (IMEE) workshop was held at the Center for Advanced Energy Studies (CAES) in Idaho Falls, Idaho, May 2–3, 2023, in support of the United States (U.S.) National Science Foundation (NSF) Established Program to Stimulate Competitive Research: Workshop Opportunities (EPSCoR-WO) program. This workshop featured keynote speakers, panels, and breakout sessions with 58 participants. Nuclear reactors need to operate under extreme service conditions, such as high temperatures, corrosive environments, and high-radiation doses. Hence, reactor components must be able to withstand those conditions. The participants envision a future where on demand manufacture of components for small modular reactors (SMRs), microreactors, and other advanced reactor designs are possible. In this future, regulatory bodies accept validated manufacturing processes and standardized feedstocks, thus eliminating the need for individual component testing. However, the necessary technologies and regulatory policies needed for this future do not exist today. Successful innovation would revolutionize the nuclear power sector, enable fast commercial development, create economic opportunities in the U.S., reduce the carbon footprint and associated risks, and promote a skilled and highly competitive workforce. The objective of the workshop was to convene world-class experts, researchers, educators, and students to identify gaps and envision solutions for five interrelated challenges for intelligent manufacturing in extreme environments. The key outcomes of the conference were: (1) to take the opportunity for researchers and educators to network and form collaborations; and (2) to produce a full report to inform policy-makers, industry, and the academic community of various challenges and opportunities in the nuclear energy sector.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Graduating Sustainable Industrial Decarbonization Solutions from the Laboratory to Real-World Deployments

Accelerating innovation and integration of industrial decarbonization technology solutions is crucial for achieving industry-wide net-zero greenhouse gas emissions targets. This can be accomplished in various ways through increased utilization of low-embodied carbon materials and the adoption of advanced manufacturing techniques in construction practices. At the National Renewable Energy Laboratory (NREL), we facilitate dialogue and action across all sectors to uncover industry needs to inform innovation, and explore ways we can help with implementation of emerging solutions in the real world. As an applied laboratory, NREL sits between academia and industry to fully bridge the gap from foundational science research to examining the feasibility of market applications. Integration of innovative technologies and solutions that are efficient, resilient, and grid-interactive will play a pivotal role in supporting a clean energy future. However, it is imperative that these solutions prioritize equitable outcomes, addressing the challenges faced by all communities. By embracing decarbonization, the construction industry can revolutionize itself, promoting sustainability, reducing carbon emissions, conserving resources, while enhancing performance and durability - all major steps toward a greener and more sustainable future.

cement↗
DOE OSTI2022

Robotic four-dimensional pixel assembly of van der Waals solids

Van der Waals (vdW) solids can be engineered with atomically precise vertical composition through the assembly of layered two-dimensional materials. However, the artisanal assembly of structures from micromechanically exfoliated flakes is not compatible with scalable and rapid manufacturing. Further engineering of vdW solids requires precisely designed and controlled composition over all three spatial dimensions and interlayer rotation. Here, we report a robotic four-dimensional pixel assembly method for manufacturing vdW solids with unprecedented speed, deliberate design, large area and angle control. We used the robotic assembly of prepatterned 'pixels' made from atomically thin two-dimensional components. Wafer-scale two-dimensional material films were grown, patterned through a clean, contact-free process and assembled using engineered adhesive stamps actuated by a high-vacuum robot. We fabricated vdW solids with up to 80 individual layers, consisting of 100 x 100 μm 2 areas with predesigned patterned shapes, laterally/vertically programmed composition and controlled interlayer angle. This enabled efficient optical spectroscopic assays of the vdW solids, revealing new excitonic and absorbance layer dependencies in MoS 2 . Furthermore, we fabricated twisted $N$-layer assemblies, where we observed atomic reconstruction of twisted four-layer WS 2 at high interlayer twist angles of >= 4°. In conclusion, our method enables the rapid manufacturing of atomically resolved quantum materials, which could help realize the full potential of vdW heterostructures as a platform for novel physics and advanced electronic technologies.

42 ENGINEERING↗
DOE OSTI2025

Electrocatalytically Upgrading Methane to Benzene in a Highly Compacted Microchannel Protonic Ceramic Membrane Reactor

This project aims to develop highly compacted microchannel protonic ceramic membrane reactors (HCM-PCMRs) for efficient and cost-effective methane dehydrogenation to aromatics (MDA, e.g., benzene). The integration of single-atom catalysis, electrocatalysis, membrane catalysis, membrane separation, and advanced manufacturing is designed to fulfill this goal. This project's success will ultimately develop a new cost-effective, efficient, and highly compacted infrastructure technology to address the flare and venting issue during oil and gas operations and other gas-to-liquid technologies. The key objectives for the three budget periods (BPs) are as follows.

02 PETROLEUM↗
DOE OSTI2025

Membrane-based Ionic Liquid Absorption System for Ultra-Efficient Dehumidification and Heating

The project team – comprising the University of Florida (UF), GTI Energy, and Modine Manufacturing – sought to develop a highly efficient heat-powered absorption cycle with combined dehumidification and heat pumping. This DOE-supported project advanced the technology from a TRL of 3 to 6, culminating in the development of a 1,000 CFM system. Key innovations implemented in the system addressed the low efficiency, size, cost, and reliability challenges of conventional absorption cycles. Specifically, the system was enabled by: (1) a semi-open cycle that allowed simultaneous dehumidification and heat recovery, (2) non-crystallizing ionic liquids (ILs) that enabled “double-effect” operation at elevated temperatures without the need for costly control equipment, (3) a compact membrane-based absorber that confined the IL and directly cooled it to achieve low dew points, and (4) a novel, highly integrated desorber–condenser assembly that reduced size, weight, and cost. The technology was developed with commercial HVAC applications in mind, particularly for separate sensible and latent cooling (SSLC), an innovation aimed at achieving independent and more efficient humidity control.

42 ENGINEERING↗
DOE OSTI2022

OPTIMIZATION OF A NUCLEAR VESSEL OUTLET FOR INCIDENT MONITORING

Classical nuclear core fluidic design techniques require improvement to better align with modern technological innovations. The US Department of Energy’s Office of Nuclear Energy (DOE-NE) Transformational Challenge Reactor (TCR) program is deploying additive manufacturing and advanced modeling and simulation to reimagine these designs. With the aid of modern computing power, computerized design optimization can be implemented to remove unwanted pressure drop while simultaneously optimizing flow structures, resulting in new opportunities to enable advanced instrumentation and monitoring capabilities.Previous development of geometric specifications for the TCR pressure vessel’s outlet plenum used design optimization to (1) limit pressure losses below 3.5 kPa (~0.5 psi) and (2) create a fluidic plane in which the temperature variation would not exceed ±5°C. This significant limit of the allowable pressure drop stems from the overarching goal of the TCR program to apply cutting edge techniques and unconventional thinking to demonstrate potential opportunities in additive manufacturing (AM).This paper expands the previous work by optimizing thermowell locations for robust measurements by explicitly modeling them and the resulting flow impacts. Additionally, a single core coolant channel was chosen to represent an event that causes an increased bulk flow temperature increase of 100°C.High fidelity unsteady Reynolds-averaged Navier-Stokes (URANS) simulations of the conjugate heat transfer problem were run in Siemen’s Star-CCM+ for this study. Next, the bulk flow temperature of a single coolant channel was increased by 100°C and was allowed to converge again. Finally, statistical analysis using a sequential probability ratio test (SPRT) was used to determine the elapsed time the thermocouples took to discover the increased bulk flow temperature.

See, Nate↗
DOE OSTI2023

The Elevated-Temperature Cyclic Properties of Powder Metallurgy-Hot Isostatic Pressed 316H and 316L Stainless Steel

Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code covers construction rules for elevated-temperature nuclear components. Microreactor developers have expressed a need for advanced manufacturing processes to fabricate microreactor components to reduce manufacturing costs. Components fabricated using manufacturing processes other than conventional techniques are not currently qualified in Section III, Division 5. An expeditious approach to qualifying an advanced manufacturing process for alloys whose wrought-product form is already qualified in Division 5 is to demonstrate the resultant properties from the advanced manufacturing process are equivalent or superior to the wrought-product form. Powder metallurgy-hot isostatic pressing (PM-HIP) is a mature technology that offers many advantages that are attractive to the microreactor industry. Preliminary data show that the elevated-temperature creep-fatigue properties of PM-HIP 316H stainless steel (SS) are reduced compared to the Wrought 316H SS, which is qualified in Section III, Division 5. Work is ongoing to identify the mechanisms responsible for the reduced creep-fatigue properties and to establish acceptance criteria to confirm the adequacy of the component for service.

316H stainless steel↗
DOE OSTI2020

Advanced Sensors and Instrumentation (ASI) Program Plan. Nuclear Energy Enabling Technologies (NEET)

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) sponsors a crosscutting technology development (CTD) program addressing common instrumentation & controls (I&C) needs in all DOE-NE sponsored programs. In 2012, DOE-NE initiated the Nuclear Energy Enabling Technology (NEET) Program to conduct research, development, and demonstration (RD&D) in crosscutting technologies that directly support and enable the development of existing, new and advanced reactor designs, and fuel cycle technologies. These technologies will advance the state of nuclear technology, improve its competitiveness, and promote continued contribution to meeting our Nation’s energy and environmental challenges. The NEET Program has spurred innovation in the field of sensors and instrumentation, advanced methods for manufacturing, and cyber security. The Advanced Sensors and Instrumentation (ASI) program is one element of the NEET CTD that has spurred innovation in the measurement science field by funding research on sensors, instrumentation and controls, communication, and advanced analytics that measure system parameters, gauge component control input, and provide power plant owners and operators critical awareness so they can plan and safely manage operational evolutions. The NEET ASI Program has carried out research and development (R&D) required to develop and deploy innovative and advanced sensors, and instrumentation and control capabilities for current and future nuclear energy systems, and to enable the advanced technologies essential to NE’s R&D efforts needed to realize mission goals. The concept of technology readiness assessment is helpful for the classification of instrumentation technology as part of the program strategy. A technology readiness assessment evaluates technology maturity using the Technology Readiness Level (TRL) scale and was pioneered by the National Aeronautics and Space Administration in the 1980s for space technology. It has recently been adopted to advance fuels and materials. The NEET ASI program objective is to mature instruments technology to TRL 6, which is “demonstration of the technology in relevant environment.” While there may be instances in which a different strategy is justified, the aim of the program is to respond to DOE program and stakeholder needs for nuclear instrumentation then hand off the technology after demonstration for integration in a more complex system, for example an irradiation test, experimental loop or a plant component such as the core, primary system or heat exchanger. A mechanism to continue some level of support from NEET ASI during and after the adoption (for example, to maintain fabrication and calibration capabilities) will be defined as the first example of technology hand off comes to fruition. In addition, several paths exist within DOE to complement NEET ASI activities to extend the maturity beyond TRL, for example through GAIN, technology commercialization funding, and small-business programs. Role of NEET ASI CINR projects in the TRL space, and integration with direct funded demonstration.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

The Institute for Advanced Composites Manufacturing and Innovation Circular Economy for Wind Workshop Report

Wind turbine blade waste is anticipated to amount to approximately 2.2 million tons or more by 2050 (more than the equivalent weight of 6 empire state buildings). However, no existing recycling technologies for the composites in wind turbines are currently at cost-parity with landfilling. As such, there is little industrial drive to recycle these materials, so they are currently buried. If it were possible to develop a circular economy for wind blades it could directly reduce material feedstock costs for many composites industries, facilitate the tremendous, anticipated growth of the domestic off-shore wind energy sector, and help the U.S. achieve net-zero manufacturing and energy generation. However, to enable circular economies for wind blades, several questions need to be answered.

17 WIND ENERGY↗
DOE OSTI2020

Colloidal Quantum Dot Photovoltaics: Current Progress and Path to Gigawatt Scale Enabled by Smart Manufacturing

Colloidal quantum dots (QDs) have lately been pursued with intense vigor for optoelectronic applications such as photovoltaics (PV), flexible electronics, displays, mid-infrared photodetectors, lasers, and single-photon emitters. These nanometer-sized semiconducting crystals can be suitably mass-produced and size-tuned via cost-effective solution-based synthetic routes to operate in the quantum size confinement regime, endowing them with a wide array of exotic optical and electronic properties. While the first potential market entry could be in displays and in niche applications such as “internet-of-things”, ultimately, the technology has the potential to influence large-scale terrestrial power generation, because it is amenable to high-throughput synthesis from Earth-abundant materials and large-area solution-based coating techniques and can be air-stable. In this Review, we chronicle the recent advances that have propelled QD PV toward commercialization and highlight potential areas for further progress. We present an account of the material compositions being explored as QDs and their various benefits, major chemical passivation and doping strategies that have been developed to allay QD surface traps, and advanced device designs deployed to maximize charge extraction. We also discuss pathways to >20% efficient QD PV and describe recent advances in high-precision and autonomous synthesis of such materials. With recent demonstrations of scalable synthesis of high-quality QDs, smart manufacturing of QDs and QD solids, and fabrication of stable solar cells under ambient conditions, we suggest that the technology is on the road to achieving maturity and technological relevance and that gigawatt per year distributed panel production sites may be within reach.

14 SOLAR ENERGY↗
DOE OSTI2023

A Case Study of Luminaire-Level Lighting Control: Lighting the Northwest Energy Efficiency Alliance (NEEA) Office in Portland, OR

What happens when advanced lighting and control systems are installed in the real world? Are the advantages and energy savings realized? By observing the design, installation, commissioning, and ongoing use of connected lighting systems in real-world settings, it is possible to identify the strengths, challenges, and points of human-technology interaction that may be new or unfamiliar to those responsible for implementing or maintaining the lighting system. Ultimately, understanding and experiencing each stakeholder’s interaction with the technology can allow the research team to synthesize feedback for manufacturers, improve industry understanding of the technology, and increase adoption. The Northwest Energy Efficiency Alliance (NEEA) office in Portland, OR, is a single-floor installation that puts tunable-white, interoperability, and luminaire-level advanced control capabilities to the test. Compared to simpler, “out-of-the-box” systems that minimize field-adjustable settings, the system utilized in this space allowed for granular field adjustments which required the system specifier, client, and programming agent to make additional decisions regarding system operation while the system was being programmed. This report communicates the observational findings from the installation, programming, and ongoing operation of an advanced office LLLC system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Additively Manufactured, Lightweight, Low-Cost Composite Vessels for Compressed Natural Gas Fuel Storage

This project will develop a process to combine AM via direct ink writing (DIW) technology for CFC printing and to use design optimization tools pioneered at LLNL, with advances in resin/composite formulation enabled by chemical and nano-material modification to produce lightweight low-cost CNG tanks. Our approach will yield sub-scale prototype composite pressure tanks equivalent to Type-5 CNG vessel designs that demonstrate a potential cost-benefit advantage. Central to our vision is using agile AM and design based on computationally informed DIW of both short and continuous CF, further coupled with high-performance thermoset polymer matrixes modified by emergent nanomaterials. Our single-stage, multi-material AM technology, combined with a decreased volume fraction of CF and an increased proportion of economically advantaged short fiber, all together drive the reduction in manufacturing time and overall cost. Importantly, reductions in continuous fiber and overall fiber volume fraction will be achieved without detriment to the mechanical strength of the composite vessel. This will be achieved by employing a single process using multi materials grading involving a thermoset resin “ink” modified with aligned nanoplatelets to leverage the efficient tortuous-path gas barrier effect, printed as an inner flexible gas barrier as the initial stage in our manufacturing process before compositionally grading the AM feedstock in real-time to transition to a rigid, structural CF-filled resin. The proposed hybrid construction is projected to achieve pressure ratings at a service range of 2,900–3,600 psi with a 3× burst safety factor comparable to conventional filament-wound composite tanks with an estimated 30–50% reduction in total manufacturing cost.

03 NATURAL GAS↗
DOE OSTI2022

Topology optimization for the design of porous electrodes

Porous electrodes are an integral part of many electrochemical devices since they have high porosity to maximize electrochemical transport and high surface area to maximize activity. Traditional porous electrode materials are typically homogeneous, stochastic collections of small-scale particles and offer few opportunities to engineer higher performance. Fortunately, recent breakthroughs in advanced and additive manufacturing are yielding new methods to structure and pattern porous electrodes across length scales. These architected electrodes are emerging as a promising new technology to continue to drive improvement; however, it is still unclear which structures to employ and few tools are available to guide their design. Here we address this gap by applying topology optimization to the design of porous electrodes. We demonstrate our framework on two applications: a porous electrode driving a steady Faradaic reaction and a transiently operated electrode in a supercapacitor. We present computationally designed electrodes that minimize energy losses in a half-cell. For low-conductivity materials, the optimization algorithm creates electrode designs with a hierarchy of length scales. Further, the designed electrodes are found to outperform undesigned, homogeneous electrodes. Finally, we present three-dimensional porous electrode designs. We thus establish a topology optimization framework for designing porous electrodes.

25 ENERGY STORAGE↗
DOE OSTI2020

NVBL (National Virtual Biotechnology Laboratory) Advanced Manufacturing for Medical Supplies for COVID-19

This virtual symposium was held to highlight the impact the U.S. Department of Energy’s (DOE) National Virtual Biotechnology Laboratory (NVBL) has had utilizing the unique capabilities of the DOE to tackle the science and technology challenges associated with COVID-19, and to discuss areas in which the NVBL can have impact in the future. With perspectives from Chris Fall, Director, Office of Science, DOE, and William A. Bookless, Principal Deputy Administrator of the National Nuclear Security Administration, the event featured Presentations from lead investigators reporting progress in: Epidemiological modeling, Therapeutics, Testing, Understanding transport of the virus, and Solving issues around supply chain challenges. In addition, keynote speakers from outside the NVBL discussed the upcoming science and technology needs in computing, testing and surveillance, and vaccines. The event was aimed at the S&T community, media, and general public.

Love, Lonnie↗
DOE OSTI2024

Power Electronics Manufacturing Improvements for Heavy-Duty Fuel Cell Vehicles

The Marel Power Solutions project, funded by the U.S. Department of Energy under Award DE-SC0023801, focused on advancing manufacturing techniques for power electronics in heavy-duty fuel cell vehicles. The research aimed to enhance system efficiency, reduce costs, and support broader adoption of hydrogen fuel cell technology. Key areas of investigation included power topology, thermal modeling, system architecture, and accessibility through software tools. Key Accomplishments: 1. Power Topology: - Developed an interleaved boost converter with optimized phase count, leveraging Marel’s proprietary Power Stacks. - Achieved reduced parasitic inductance and resistance, enabling high efficiency in DC-DC converters. 2. Thermal Modeling: - Integrated innovative cooling systems into compact Silicon Carbide (SiC) modules. - Simulations demonstrated the ability to dissipate significant heat (up to 7.5 kW), ensuring device reliability under heavy loads. 3. System Architecture: - Utilized simulation tools to analyze the impact of various fuel cell and vehicle parameters on efficiency. - Highlighted the role of smaller, modular improvements, such as enhanced DC-DC converters, in achieving system-wide gains. 4. Accessibility: - Evaluated and implemented MATLAB/Simulink code generation tools for real-world hardware applications. - Demonstrated the potential for rapid prototyping of custom power systems with reduced development costs. Impact and Benefits: - Efficiency and Cost Reduction: Marel’s cooling technology enhances SiC die performance, reducing the number of dies required and overall system size. - Scalability and Flexibility: The innovations support tailored solutions for diverse applications, from mass transit to mining vehicles. - Sustainability: The research promotes the integration of electrification technologies, helping meet rising energy demands sustainably. Conclusion: The project’s outcomes advance the state of power electronics for hydrogen fuel cell vehicles, enabling more efficient, compact, and cost-effective solutions. These developments lay a foundation for future innovation, contributing to the broader adoption of clean energy technologies in transportation and other industries.

08 HYDROGEN↗
DOE OSTI2025

REIMAGINING HEAT EXCHANGERS FOR NEXT GENERATION ENVIRONMENTAL SYSTEMS

Air-to-refrigerant heat exchangers (HXs) are essential components in space conditioning, refrigeration, and power systems, and recent efforts have focused on making these devices more compact, reducing refrigerant charge and lowering manufacturing costs. Historically, HX innovation has been limited by available computational resources, design tools, and manufacturing constraints. The best available technologies utilize tube-fin and micro- or macro-channel tubes with fins, which are not necessarily the optimal designs achievable with current technology. In this paper, we highlight the latest advancements in air-to-refrigerant HXs, specifically emphasizing innovations achieved through shape and topology optimization. A multi-scale design optimization approach is introduced, alongside similar methods in literature, which enable highly sophisticated shape-optimized tube designs with more than 50% reduction in size and 25% reduction in refrigerant charge, essential for A3 refrigerant charge limit compliance. The frameworks integrate traditional heat and mass transfer science with state-of-the-art machine learning, genetic algorithms, and adjoint algorithms to create novel designs. While many of these innovative designs may not be manufacturable using conventional methods, they allow us explore the boundaries of what is possible. These novel air-to-refrigerant HXs are key enablers for ultra-low-refrigerant charge heat pump and refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Sustainability of the U.S. Manufacturing Sector: Use of the United Nations Sustainable Development Goals

The United Nations' 17 Sustainable Development Goals (SDGs) aim to improve health and education, reduce inequality, and encourage economic growth, while also preserving or improving the conditions of our oceans and forests. Pursuing these SDGs would mean $12 trillion in economic opportunities for companies, while also improving the lives of all people and bettering the planet. Some manufacturing companies are already focusing on sustainability, but not all. In 2019, almost 30% of National Association of Manufacturers members did not have a sustainable policy, goals, or program in place. Business drivers for sustainability and the SDGs are similar, with focuses on economic growth and consumer demands. Despite the shortcomings of the SDGs, they represent an opportunity for manufacturing companies to further improve energy, material efficiency, and productivity. This report evaluates the SDGs and the manufacturing sector. The manufacturing sector was analyzed using the technology assessments (TAs) introduced in the 2015 Quadrennial Technology Review (QTR) review, which focused on concepts, challenges, and solutions to meet the United States' energy needs. Annual or sustainability reporting of companies performing work in one of those TAs were analyzed for mentions of the SDGs. The call-out boxes throughout this report provide examples of companies making progress toward the SDGs. The possible overlap between the SDGs and the Advanced Manufacturing Office (AMO) was also evaluated. The TAs in the 2015 QTR Review were furthered with detailed targets in the draft Multi-Year Program Plan (MYPP) for Fiscal Years 2017-2021. Direct and likely relationships between the SDGs and the TAs were established. Positives, challenges, SDG-related literature, and future steps are also discussed in this report.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Challenges in synthesis of heterostructures

Developing the ability to reproducibly prepare materials drives the advancement of human technology. Trends in historical advances and extrapolation of current technologies suggest that the next logical step is developing the ability to control structure and composition at near atomic scales in device manufacturing to take advantage of emergent properties discovered in 2D materials and heterostructures. This article reviews a subset of synthetic approaches used to prepare heterostructures, outlining key reaction steps, and how experimental parameters are used to control which product forms. The positive attributes of each synthesis approach are discussed along with some of their limitations. The elemental reactant (MER) approach is discussed in more depth.

36 MATERIALS SCIENCE↗