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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Relative permeability of gas and water flow in hydrate-bearing porous media: A micro-scale study by lattice Boltzmann simulation

The water-gas relative permeability is an important parameter to characterize multiphase flow in sediments. To study the water-gas relative permeability of hydrate-bearing porous media, multiphase flow simulations were carried out at the pore scale using the lattice Boltzmann method. In this work, the effects of hydrate saturation and hydrate-growth habits on the water-gas relative permeability, which is scaled by the relative permeability considering the hydrate only, were evaluated in a two-dimensional porous medium. Results show that the increase of hydrate saturation causes the decrease of water-gas effective permeability as expected. However, the effect of hydrate saturation on the water-gas relative permeability is different from that of hydrate saturation on the water-gas effective permeability. The water-gas relative permeability increases with the increase of hydrate saturation in the pore-filling case. The water-gas relative permeability decreases with the increase of hydrate saturation in the grain-coating case. The wettability of solid phase has a different effect on the relative permeability of wetting phase and nonwetting phase. The Jamin effect (phase blocking) was observed and may exist in the production of gas from natural gas hydrate reservoirs. This seriously affects the multiphase flow characteristics. The changes of microscale fluid distribution effect the changes of water-gas relative permeability. The relationship between the water-gas relative permeability and the characterization parameters of microscale fluid distribution was analyzed.

58 GEOSCIENCES↗
DOE OSTI2022

Vanadium (II) Sulfate for the Reductive Leaching of Chalcopyrite: Replacing Smelting with Electrolysis for Copper Production

The demand for copper is expected to outpace supply in the coming decades due in part to the emergence of wind and solar technologies, which require about five times as much copper as traditional energy sources. This work introduces a potentially transformative hydrometallurgical process to extract copper from chalcopyrite, and thereby sustain a high rate of copper production throughout the 21 st century. Chalcopyrite is reacted with vanadium (II) sulfate for the first time to enable the rapid, clean, and complete recovery of copper. Reactions between 39 g/L copper concentrate, 1 M vanadium (II) sulfate, and various concentrations of sulfuric acid yielded a final product of solid copper sulfate, which was characterized by X-ray diffraction (XRD) and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS) analysis. The solid products were leached in a subsequent step to demonstrate copper yields ranging from 95–99%. The vanadium (II) ion may be regenerated by an electrolysis unit that leverages advances in vanadium flow battery technologies.

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

Combined electrocoagulation-microfiltration-membrane distillation for treatment of hydraulic fracturing produced water

Hydraulic fracturing flowback and produced water is a highly impaired wastewater containing dissolved salts polar and non-polar organic compounds, oil and surfactants. Here a combined electrocoagulation - microfiltration – membrane distillation process has been used to treat this wastewater. Electrocoagulation followed by microfiltration was used to pretreat the wastewater prior membrane distillation. The initial total dissolved solids (TDS) concentration was extremely high being 245,300 mg L -1 . After electrocoagulation, the total organic carbon (TOC) was reduced from 120 mg L -1 to 64 mg L -1 . Tangential flow microfiltration using a 0.1 μm pore size polyethersulfone membrane was used to separate the particulate matter after electrocoagulation and to further reduce the TOC to 44 mg L -1 . Membrane distillation was used to desalinate the pretreated produced water resulting in a high quality treated water (TDS of 56 mg L -1 and TOC 1 mg L -1 ). Three membranes with very different surface morphology were used: commercially available polyvinylidene fluoride, electrospun poly(vinylidene fluoride-co-hexafluoropropylene) nanofibers and multiwalled carbon nanotube coated polytetrafluoroethylene. The TDS in the retentate increased to over 350,000 mg L -1 . During membrane distillation, the temperature of the feed tank was maintained at 36 °C while the feed entered the module at 60 °C in order to minimize scaling on the membrane. The surface properties of an ideal membrane that is resistant to wetting and provides high flux is likely to depend on the TDS and properties of the wastewater.

42 ENGINEERING↗
DOE OSTI2022

Predicting extreme anisotropy and shape variations in impact testing of tantalum single crystals

We report recent Taylor cylinder impact tests carried out for Ta single crystals showed strong variations in dimensional changes for different crystallographic directions aligned with the cylindrical axis. In order to capture the effect of crystallography on the deformation characteristics and final shapes of the impacted cylinders, a single crystal material subroutine is adapted and embedded in the solid mechanics/dynamics Finite Element solver Abaqus to simulate the aforementioned single crystal Ta Taylor impact experiments. Details of the coupled model implementation, and insights on the role played by single crystal anisotropic flow on the deformation behavior across a broad range of strain rates and temperatures for different single crystal orientations are presented and discussed. We demonstrate the predictive capability of the adopted crystal plasticity model to capture the significant role played by crystal orientation-induced anisotropy, as well as strain hardening and adiabatic heating, on the dynamic deformation response of crystalline materials. This re-emphasizes the need of microstructure-aware models to improve the accuracy of simulations for high-consequence engineering design.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Are Contact Angle Measurements Useful for Oxide-Coated Liquid Metals?

This work establishes that static contact angles for gallium-based liquid metals have no utility despite the continued and common use of such angles in the literature. In the presence of oxygen, these metals rapidly form a thin (~1–3 nm) surface oxide “skin” that adheres to many surfaces and mechanically impedes its flow. This property is problematic for contact angle measurements, which presume the ability of liquids to flow freely to adopt shapes that minimize the interfacial energy. We show here that advancing angles for a metal are always high (>140°)—even on substrates to which it adheres—because the solid native oxide must rupture in tension to advance the contact line. The advancing angle for the metal depends subtly on the substrate surface chemistry but does not vary strongly with hydrophobicity of the substrate. During receding measurements, the metal droplet initially sags as the liquid withdraws from the “sac” formed by the skin and thus the contact area with the substrate initially increases despite its volumetric recession. Furthermore, the oxide pins at the perimeter of the deflated “sac” on all the surfaces are tested, except for certain rough surfaces. With additional withdrawal of the liquid metal, the pinned angle gets smaller until eventually the oxide “sac” collapses. Thus, static contact angles can be manipulated mechanically from 0° to >140° due to hysteresis and are therefore uninformative. We also provide recommendations and best practices for wetting experiments, which may find use in applications that use these alloys such as soft electronics, composites, and microfluidics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Quantum Dot Based Solid-State Radiation Detectors

The detection and accurate identification of nuclear material is critical to the advancement of national security, medical technology, and environmental prosperity. The gold standard solid-state detector HPGe, suffers from high manufacturing costs and the need to operate at cryogenic temperatures to ensure reliable energy resolution. The other most common solid-state detector, cadmium zinc telluride (CZT), has the ability to operate at room temperature, but the grow process results in impurities decreasing performance. In this paper we have developed a continuous flow synthesis able to mass produce targeted size cadmium selenide quantum dots. The implementation of these QDs in QD/MEH-PPV composites has the ability to rival HPGe energy resolution at room temperature.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Overdriven Shocks: Recapturing a Lost Capability

Wallace’s theory for overdriven shocks in solids provides a theoretical framework for the strength of materials in the strong shock regime at strain rates unobtainable by current experimental means. Using irreversible thermodynamics, this theory incorporates heat and plastic flow as dissipative mechanisms under shock conditions allowing for the calculation of properties such as deviatoric stresses, plastic strains, and plastic strain rates. Though the theory is over four decades old, it has been used to calculate the strength behavior of only a small handful of metals. In this work, we have recaptured the ability to conduct this analysis, and two crucial aspects of the overdriven theory will be discussed: 1) the modeling assumptions that comprise this theoretical approach and 2) what information is needed to calculate the strength behavior for new materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Structural uniformity and compositional homogeneity of solid-phase alloyed rod

Solid-phase processes have emerged as an alternative to fusion-based alloying to avoid coarse microstructures, undesirable phase formation, and high energy consumption. However, achieving uniform distribution of alloying elements during friction-based processing remains challenging due to highly heterogeneous thermomechanical conditions. This work evaluates the structural uniformity and compositional homogeneity of Al–Cu–Zn alloyed rods produced by friction extrusion (FE) and establishes the role of the rotational speed to feed rate ratio (N/V) on alloying effectiveness. A systematic matrix of FE experiments was conducted at constant extrusion ratio with N/V values ranging from 3.7 to 300. Compositional uniformity was assessed along the rod length (ICP-OES), in three dimensions (X-ray computed tomography), and at the microscale (SEM–EDS), supported by a gray-level co-occurrence matrix (GLCM)–based homogeneity metric. Smoothed particle hydrodynamics (SPH) simulations were used to reveal material flow and thermomechanical fields. Results show that N/V = 100 produces a high-shear mixing zone that eliminates the unmixed core and enables near-full dissolution and dispersion of Cu and Zn. At lower N/V, a laminar flow region persists at the rod center, causing segregation and large composition gradients. The combined experimental–computational analysis provides mechanistic insight into the transition from fragmented particle dispersion to thermomechanically assisted metallurgical mixing. This study establishes processing–structure relationships for solid-phase alloying and provides guidance for achieving homogenized compositions comparable to wrought alloys via rapid, scalable FE processing.

Aluminum↗
DOE OSTI2023

MyCrunchGPT: A LLM Assisted Framework for Scientific Machine Learning

Scientific machine learning (SciML) has advanced recently across many different areas in computational science and engineering. Here, the objective is to integrate data and physics seamlessly without the need of employing elaborate and computationally taxing data assimilation schemes. However, preprocessing, problem formulation, code generation, postprocessing, and analysis are still time- consuming and may prevent SciML from wide applicability in industrial applications and in digital twin frameworks. Here, we integrate the various stages of SciML under the umbrella of ChatGPT, to formulate MyCrunchGPT, which plays the role of a conductor orchestrating the entire workflow of SciML based on simple prompts by the user. Specifically, we present two examples that demonstrate the potential use of MyCrunchGPT in optimizing airfoils in aerodynamics, and in obtaining flow fields in various geometries in interactive mode, with emphasis on the validation stage. To demonstrate the flow of the MyCrunchGPT, and create an infrastructure that can facilitate a broader vision, we built a web app based guided user interface, that includes options for a comprehensive summary report. The overall objective is to extend MyCrunchGPT to handle diverse problems in computational mechanics, design, optimization and controls, and general scientific computing tasks involved in SciML, hence using it as a research assistant tool but also as an educational tool. While here the examples focus on fluid mechanics, future versions will target solid mechanics and materials science, geophysics, systems biology, and bioinformatics.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Insights into scale translation of methane transport in nanopores

Accurate prediction of flow behavior in shale matrix is critical for efficient development of shale gas reservoirs. In these systems, the majority of pores are in the nano-size range. As a result, continuum-based approaches may not be appropriate to simulate flow in such systems. Molecular dynamics (MD) simulations are capable of capturing the relevant microscale physics. Their relatively high computational expense, however, restricts MD simulations to rather small systems and domains. This limitation creates a gap between computational need of macroscale systems and capabilities of MD simulations. The lattice Boltzmann method (LBM) is a suitable candidate to bridge this gap. In this work, the multiple-relaxation-time (MRT)-LBM is used to study methane transport in nano-size pores. Adsorption effects near solid boundaries, as well as non-ideal behavior of fluids, are accounted for via incorporating appropriate force terms in LBM. In this work, parameters associated with the force terms in the equation of state are studied in detail, and a workflow is proposed to determine optimal values of these parameters for gas flow in slit pores. Specifically, we establish these parameters such that the range of density values that the model is able to simulate is maximized. We demonstrate this workflow by simulating gas flow where velocity and density profiles from MD simulations are used as reference data. Results from LBM simulations are in good agreement with MD reference data for pores that are 4 nm in width or larger. Moreover, we propose a preconditioning scheme to improve the stability of LBM in dealing with complex geometries. The robustness of this scheme is demonstrated by simulating several roughness geometries. This work motivates the use of LBM in scale translation of the physics of mass transport in more complex permeable media.

03 NATURAL GAS↗
DOE OSTI2021

TEMPO allegro: liquid catholyte redoxmers for nonaqueous redox flow batteries

Redoxmers are organic active molecules storing energy in redox flow batteries (RFBs). Liquid redoxmers represent an extreme scenario where maximum concentration may be achieved by minimizing supporting solvents, thus maximizing the energy density of RFBs. Herein, a series of (2,2,6,6-tetramethylpiperidin-1-yl)oxyl (TEMPO)-based high potential (catholyte) liquid redoxmers, TEMPO-EG1, TEMPO-EG2, and TEMPO-EG3, were developed by incorporating polyethylene glycol (PEG) chains. Such modifications not only afford dramatic physical changes from solid to liquid and full miscibility in acetonitrile, but also impact the redox behavior. DFT calculations indicate that the incorporated PEG chains impact the charge distribution, which may account for the electrochemical changes. Importantly, compared to our previous liquid catholytes, the new redoxmers exhibit lower viscosity, which is desired for enhancing high concentration cycling performance. Furthermore, by using a hybrid flow cell, TEMPO-EG1 demonstrated more than 70% capacity retention over 100 cycles at 0.1 M and 66% capacity retention at 0.5 M, affording excellent cyclability at various concentrations. The study exemplifies how molecular engineering tuned the rheological properties of redoxmers, such as viscosity, to improve the high concentration cycling performance of RFBs, which may represent a promising avenue for a high energy density and low-cost flow battery system.

25 ENERGY STORAGE↗
DOE OSTI2022

Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept

This report summarizes the work performed for the U. S. Department of Energy/National Energy Technology Laboratory (DOE/NETL) under Cooperative Agreement DE-FE0026211 entitled “Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept”. The overall objective of this project was to develop and evaluate a solid oxide fuel cell (SOFC) stack configuration based on a novel prime-surface interconnect design for a broad range of power generation applications. The prime-surface is a one-piece metallic interconnect that incorporates both fuel and oxidant flow fields with peaks on one side of the interconnect serving as flow channels (valleys) on the other side. (One example is the egg-carton shaped interconnect design.) This stack technology has several attractive features including reduced stack weight and volume, decreased performance losses in stacking, improved sealing, versatility in incorporation of different types of cell construction (thin-film cells or sintered cells) and flexibility in gas flow configuration (cross-flow, co-flow or counter-flow). These features lead to lower cost, better performance, and enhanced reliability for the stack. The R&D work of this project focused on demonstrating fabrication, operability and cost effectiveness of the stack design and was conducted by University of California, San Diego (UCSD) in conjunction with OxEon Energy (OxEon). The key technical activities of this project involved prime-surface interconnect design and fabrication development; supported thin-film cell structure development; stack development; stack operation demonstration; and stack cost assessment. The results of these activities are summarized in this report.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Liquid metal walls

Here, the plasma performance of fusion devices depends strongly on the chosen wall materials. Solid plasma-facing components (PFCs) are predominantly used in present devices, and are the most investigated candidates for fusion designs. High-Z materials such as tungsten (W) are the leading solid PFC material candidates. To date, a material choice that scales to steady-state reactor conditions has not been identified. Moreover, if plasma transient events such as edge-localized modes and disruptions cannot be altogether avoided or sufficiently mitigated, the projected peak heat and particle loads far exceed the power exhaust capabilities of solids. Liquid metal (LM) PFCs represent an intrinsic self-healing boundary that are both resilient to surface damage from transients, and that could handle high steady-state heat and particle fluxes. Flowing LM PFCs can be designed to remove “slag,” the buildup of material erosion due to plasma-material interactions, including charge exchange sputtering in the main chamber. Further, LM offer the prospect to manage hydrogenic species otherwise retained in the PFCs, which is important from a safety and inventory standpoint. The two most promising LMs are lithium (Li) and tin (Sn), although Sn–Li eutectics may be considered. While Sn offers a higher temperature window with low vapor pressure and low hydrogen retention, Li offers the prospect of enhanced energy confinement and higher acceptable core contamination limits, and this section focuses on Li PFCs. An LM PFC development research program developed LM PFC concepts for a nuclear fusion device via engineering design calculations, single-effect experiments, and staged prototypical experiments. A self-consistent design window was identified with liquid Li flow speeds ~5–10 m/s; plasma contamination was negligible for predicted Li evolution rates. While these preconceptual designs hold promise, there is substantial R&D needed to advance the technical readiness levels of LM PFCs for application to fusion power plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Local heat transfer measurement in a volumetrically heated TPMS lattice using distributed optical fiber thermal sensing

As additive manufacturing continues to reduce design constraints on heat exchange geometries, methods for high-fidelity local heat transfer measurements in nonconventional channel geometries are critical to their continued development. This study presents a novel method for measuring local heat transfer performance in volumetrically heated lattices using a distributed optical fiber temperature sensor. A diamond-type triply periodic minimal surface (TPMS) lattice, 3D-printed from a conductive polymer, was Joule heated while it was convectively cooled with air. Temperature measurements were taken at the solid–fluid interface across 14 internal locations using a single optical fiber over the Reynolds number range 800–2750. The TPMS lattice achieved up to 312% higher heat transfer coefficients compared to developing flow in a straight tube. A Nusselt number correlation was developed for the diamond TPMS, which showed good agreement with data collected for comparable geometries available in literature. In conclusion, this study presents a robust and new method for experimental measurement of the heat transfer coefficient in complex geometries and helps to understand and quantify the exceptional performance of TPMS heat transfer geometries.

TPMS↗
DOE OSTI2020

An in situ shearing x-ray measurement system for exploring structures and dynamics at the solid–liquid interface

Revealing interfacial structure and dynamics has been one of the essential thematic topics in material science and condensed matter physics. Synchrotron-based x-ray scattering techniques can deliver unique and insightful probing of interfacial structures and dynamics, in particular, in reflection geometries with higher surface and interfacial sensitivity than transmission geometries. We demonstrate the design and implementation of an in situ shearing x-ray measurement system, equipped with both inline parallel-plate and cone-and-plate shearing setups and operated at the advanced photon source at Argonne National Laboratory, to investigate the structures and dynamics of end-tethered polymers at the solid-liquid interface. With a precise lifting motor, a micrometer-scale gap can be produced by aligning two surfaces of a rotating upper shaft and a lower sample substrate. A torsional shear flow forms in the gap and applies tangential shear forces on the sample surface. The technical combination with nanoscale rheology and the utilization of in situ x-ray scattering allow us to gain fundamental insights into the complex dynamics in soft interfaces under shearing. In this work, we demonstrate the technical scope and experimental capability of the in situ shearing x-ray system through the measurements of charged polymers at both flat and curved interfaces upon shearing. Furthermore, through the in situ shearing x-ray scattering experiments integrated with theoretical simulations, we aim to develop a detailed understanding of the short-range molecular structure and mesoscale ionic aggregate morphology, as well as ion transport and dynamics in soft interfaces, thereby providing fundamental insight into a long-standing challenge in ionic polymer brushes with a significant technological impact.

36 MATERIALS SCIENCE↗
DOE OSTI2024

C Modules Enrichment

Module C1 discusses the step in the nuclear fuel cycle where the UF6 solid in cylinders from the conversion plant is processed to enrich the percentage of U-235 from 0.711% to the 3–5% typical of the enrichment used for light-water reactor nuclear fuel fabrication. It involves receipt of UF6 feed stock in 12.5 ton cylinders, enrichment operations, formation of enriched UF6 solid, and shipment of 2.3 ton cylinders to fuel fabricators. In this module, “SWU” is taken as shorthand for kg-SWU, the formal units for enrichment work, assuming that heavy metal mass flows will be gauged in kg.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Plastic deformation of single crystals of the equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy in tension and compression from 10 K to 1273 K

In this report the plastic deformation behavior of single crystals of the quinary, equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy (HEA) with the face-centered cubic structure has been investigated in tension and compression as a function of crystal orientation and temperature from 10 K to 1373 K. The critical resolved shear stress (CRSS) for {111}<110> slip at room temperature is 42-45 MPa. It does not depend much on crystal orientation (i.e., the Schmid law holds true) and the sense (tension vs. compression) of the applied load. The CRSS for {111}<110> slip increases with the decrease in temperature, without showing any significant inertia effects at cryogenic temperatures below 77 K. Extrapolation from the measured yield stresses down to 10 K yields a CRSS value at 0 K of 168 MPa. At cryogenic temperatures, the measured strain-rate sensitivity of flow stress is consistent with a very small activation volume. The concept of stress equivalence holds true both for the temperature dependence of CRSS and the stress dependence of activation volume, indicating that solid-solution hardening is the major strengthening mechanism. Deformation twinning occurs at 77 K but not at room temperature, resulting in higher tensile elongation to failure at 77 K than at room temperature. Deformation twinning at 77 K occurs at a shear stress of 378 MPa on conjugate ($\bar1\bar11$) planes in the form of Lüders deformation after large plastic strain (about 85%) achieved by the stage I (easy glide) and stage II (linear work-hardening) deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

CFD analysis of a solid pin-fueled small modular fluoride salt-cooled reactor

A computational fluid dynamics (CFD) study is performed for the pre-conceptual solid pin-fueled small modular fluoride salt-cooled reactor developed by the Oak Ridge National Laboratory (ORNL). The solid and fluid regions in a 1/12th section of a fuel assembly are modeled. The solid region includes fuel and non-fuel pins, with heat generation in the active region of the fuel pins. Two different power profiles, uniform and center-peaked, are considered. The FLiBe coolant flows from the bottom to the top of the core, parallel to the bank of fuel and non-fuel pins. The k-ω shear-stress transport (SST) model is chosen as the baseline turbulence model. The effects of grid refinement, inlet turbulence specification, and turbulence models on the temperature and pressure drop predictions are studied. Turbulence model sensitivity is investigated by comparing the results from the k-ω SST model with other two-equation models (k-ω baseline or BSL and k-ε realizable) as well as with anisotropic Reynolds stress transport models (linear pressure-strain and stress-BSL). Here the results show that the choice of turbulence model has a significant impact on the pin temperature and bundle pressure drop predictions. The results from the baseline turbulence model show good agreement between the fuel pin temperatures and bundle pressure drop values predicted using a subchannel model previously developed by the authors of the present study.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗