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DOE OSTI2019

Microstructure and Mechanical Properties of Ni-based Superalloy K418 Produced by the Continuous Unidirectional Solidification Process

Adopting effective strategies to control the solidification structure of Ni-based superalloys is a very interesting subject for metallurgists. Despite the achievement of developing and applying the continuous unidirectional solidification process in simple alloys, the utilization of this process for K418 alloys has been ignored. The microstructure and mechanical properties of a K418 alloy ingot produced by the continuous unidirectional solidification process were investigated. We found that the γ dendrites were typically cross-shaped in the transverse section. The orientation of surviving grains along the casting direction was <001> during competitive growth. The secondary dendrite arm spacing was 32.3 ± 2.5 μm at a cooling rate of 1.75 ± 0.35 °C/s from the surface to the center of the K418 alloy ingot. Due to the higher cooling rate than that of the conventional casting process, a more uniform microstructure and finer γ′ precipitation were obtained in the ingot. Thus, compared with the conventional casting, the tensile strength and the elongation are increased by 8.4 and 21.3%, respectively, at 25 °C. The tensile strength and elongation increased by 15.2 and 49.3%, respectively, at 800 °C. In addition, the fracture surfaces exhibited numerous typical dimples and dendritic fracture characteristics.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Method for Continuous Monitoring of Electrospray Ion Formation

A method for continuously monitoring the performance of electrospray ionization without the addition of hardware or chemistry to the system is demonstrated. In the method, which we refer to as SprayDx, cluster ions with solvent vapor natively formed by electrospray are followed throughout the collection of liquid chromatography–selected reaction monitoring data. The cluster ion extracted ion chromatograms report on the consistency of the ion formation and detection system. The data collected by the SprayDx method resemble the data collected for postcolumn infusion of analyte. The response of the cluster ions monitored reports on changes in the physical parameters of the ion source such as voltage and gas flow. SprayDx is also observed to report on ion suppression in a fashion very similar to a postcolumn infusion of analyte. We anticipate the method finding utility as a continuous readout on the performance of electrospray and other atmospheric pressure ionization processes. .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

On the periodic solutions of the Michelson continuous and discontinuous piecewise linear differential system

Applying new results from the averaging theory for continuous and discontinuous differential systems, we study the periodic solutions of two distinct versions of the Michelson differential system: a Michelson continuous piecewise linear differential system and a Michelson discontinuous piecewise linear differential system. The tools here used can be applied to general nonsmooth differential systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Continuous solutions to a class of first-order fuzzy differential equations with discontinuous coefficients

In this paper, we study the continuity of solution functions to a class of fuzzy differential equations (FDEs) in the form y{sup ′}(t)=((φ(t))/((t−α){sup p}))⊙y(t)+ψ(t), where the coefficient function ((φ(t))/((t−α){sup p})) is a discontinuous function at the point t=α and α is an inner point of the interval under study. At first, the continuity of solutions for the crisp case of the problem is investigated and those results are extended to the fuzzy case of the problem from the view point of strongly generalized differentiability (G-differentiability). Next, we obtain explicit formulas of solutions and the conditions of their existence for a special class of these problems. Finally, the results are illustrated by solving some examples.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Integrating continuous atmospheric boundary layer and tower-based flux measurements to advance understanding of land-atmosphere interactions

The atmospheric boundary layer mediates the exchange of energy, matter, and momentum between the land surface and the free troposphere, integrating a range of physical, chemical, and biological processes and is defined as the lowest layer of the atmosphere (ranging from a few meters to 3 km). In this review, we investigate how continuous, automated observations of the atmospheric boundary layer can enhance the scientific value of co-located eddy covariance measurements of land-atmosphere fluxes of carbon, water, and energy, as are being made at FLUXNET sites worldwide. We highlight four key opportunities to integrate tower-based flux measurements with continuous, long-term atmospheric boundary layer measurements: (1) to interpret surface flux and atmospheric boundary layer exchange dynamics and feedbacks at flux tower sites, (2) to support flux footprint modelling, the interpretation of surface fluxes in heterogeneous terrain, and quality control of eddy covariance flux measurements, (3) to support regional-scale modeling and upscaling of surface fluxes to continental scales, and (4) to quantify land-atmosphere coupling and validate its representation in Earth system models. Adding a suite of atmospheric boundary layer measurements to eddy covariance flux tower sites, and supporting the sharing of these data to tower networks, would allow the Earth science community to address new emerging research questions, better interpret ongoing flux tower measurements, and would present novel opportunities for collaborations between FLUXNET scientists and atmospheric and remote sensing scientists.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

Process Development for Hydrothermal Liquefaction of Algae Feedstocks in a Continuous-Flow Reactor

Wet algae slurries can be converted into an upgradeable biocrude by hydrothermal liquefaction (HTL). High levels of carbon conversion to gravity-separable biocrude product were accomplished at relatively low temperature (350 °C) in a continuous-flow, pressurized (sub-critical liquid water) environment (20 MPa). As opposed to earlier work in batch reactors reported by others, direct oil recovery was achieved without the use of a solvent and biomass trace components were removed by processing steps so that they did not cause process difficulties. High conversions were obtained even with high slurry concentrations of up to 35 wt% of dry solids. Catalytic hydrotreating was effectively applied for hydrodeoxygenation, hydrodenitrogenation, and hydrodesulfurization of the biocrude to form liquid hydrocarbon fuel. Catalytic hydrothermal gasification was effectively applied for HTL byproduct water cleanup and fuel gas production from water soluble organics, allowing the water to be considered for recycle of nutrients to the algae growth ponds. As a result, high conversion of algae to liquid hydrocarbon and gas products was found with low levels of organic contamination in the byproduct water. All three process steps were accomplished in bench-scale, continuous-flow reactor systems such that design data for process scale-up was generated.

algae↗

DOE OSTI2018

Radiation dose rate distributions of spent fuel dry casks estimated with MAVRIC based on detailed geometry and continuous-energy models

This study presents a detailed comparison of the dose rate distributions of a dry TN–32 fuel cask with two geometry models and two cross-sectional datasets. The accuracies of radiation dose rate estimation and computational efficiencies of each geometry model with two cross-sectional data-sets are compared. The use of automated variance reduction techniques can significantly improve the computational efficiency of such a realistic, deep penetration problem that involves radiation transport from different volumetric sources, thereby eliciting only a small statistical error. Monaco with Automated Variance Reduction using Importance Calculations (MAVRIC) is a computational sequence within the SCALE 6.2 code package based on consistent adjoint driven importance sampling (CADIS), a type of automated variance reduction technique. Homogenous and full fuel assembly models are built herein, and two nuclear cross-section libraries (V7–200N47G and continuous energy) are applied in this work. Based on the detailed comparisons, we found that neutron dose rate estimation is more dependent on geometry modeling than on cross-section data. For neutron-induced gamma rays, the dose rate distribution depends on both the spatial self-shielding effect and the cross-section library. The primary gamma rays respectively contribute to the total dose rate by ~91% and ~ 99% on side and top surfaces, and the dose rate accuracy is more dependent on the cross-section library than on geometry modeling. In terms of the computation efficiency and efforts spent on geometry modeling, the homogenous fuel assembly model with the MG library can produce an acceptable dose rate distribution, but the detailed fuel assembly model with the continuous-energy library is required for more precise dose rate estimation.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2019

Continuous-energy Monte Carlo neutron transport on GPUs in the Shift code

Here, a continuous-energy Monte Carlo neutron transport solver executing on GPUs has been developed within the Shift code. Several algorithmic approaches are considered, including both history-based and event-based implementations. Unlike in previous work involving multigroup Monte Carlo transport, it is demonstrated that event-based algorithms significantly outperform a history-based approach for continuous-energy transport as a result of increased device occupancy and reduced thread divergence. Numerical results are presented for detailed full-core models of a small modular reactor (SMR), including a model containing depleted fuel materials. These results demonstrate the substantial gains in performance that are possible with the latest-generation of GPUs. On the depleted SMR core configuration, an NVIDIA P100 GPU with 56 streaming multiprocessors provides performance equivalent to 90 CPU cores, and the latest V100 GPU with 80 multiprocessors offers the performance of more than 150 CPU cores.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2019

Continuous on-sun solar thermochemical hydrogen production via an isothermal redox cycle

Solar thermochemical hydrogen production from water is a path towards a carbon-free sustainable hydrogen economy. Here, isothermal on-sun hydrogen production is demonstrated using active iron aluminate (hercynite) particles contained in dual fluidized bed reactors. The two fluidized beds were held in a single cavity solar receiver that was heated with a 10 kW high flux solar furnace. During 8 h of on-sun testing, 5.3 L of H 2 were generated with an average productivity of 597 umol H 2 /g using an intermittent process with optimized redox cycle times. Redox cycling was performed isothermally and continuously with equivalent oxidation and reduction times producing 547 umol H2/g over two cycles. These results show excellent agreement with the H 2 production measured in an 800X scaled-down electrically heated laboratory stagnation flow reactor and surpass on-sun H 2 production of current benchmark materials. The effect of environmental variability on the incident solar radiation and hydrogen production is evaluated during on-sun testing. Finally, a discussion of the important factors for scalability of the process to commercial applications is provided, highlighting the importance of robust containment and active materials. This work links current materials research and development with commercial implementation in an on-sun process and demonstrates the viability of solar thermochemical hydrogen production that leverages continuous isothermal redox cycling.

08 HYDROGEN↗

DOE OSTI2018

Reachability analysis of linear dynamic systems with constant, arbitrary, and Lipschitz continuous inputs

This paper sets forth a method for reachability analysis of linear dynamic systems in continuous time that can be used to compute time-domain bounds of states and outputs with floating-point precision. The focus is on the particular initial conditions and inputs that cause state or output trajectories to attain their extreme values in time. Inputs can be constant, arbitrary, or Lipschitz continuous waveforms. Uncertainties in initial conditions and inputs are modeled using zonotopes. The calculations exploit the definition of zonotopes and the modal information of the linear system dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Continuous culture of anaerobic fungi enables growth and metabolic flux tuning without use of genetic tools

Anaerobic gut fungi (AGF) have potential to valorize lignocellulosic biomass owing to their diverse repertoire of carbohydrate-active enzymes (CAZymes). However, AGF metabolism is poorly understood, and no stable genetic tools are available to manipulate growth and metabolic flux to enhance production of specific targets, e.g., cells, CAZymes, or metabolites. Herein, a cost-effective, Arduino-based, continuous-flow anaerobic bioreactor with online optical density control is presented to probe metabolism and predictably tune fluxes in Caecomyces churrovis. Varying the C. churrovis turbidostat setpoint titer reliably controlled growth rate (from 0.04 to 0.20 h −1 ), metabolic flux, and production rates of acetate, formate, lactate, and ethanol. Bioreactor setpoints to maximize production of each product were identified, and all continuous production rates significantly exceed batch rates. Formate spike-ins increased lactate flux and decreased acetate, ethanol, and formate fluxes. The bioreactor and turbidostat culture schemes demonstrated here offer tools to tailor AGF fermentations to application-specific hydrolysate product profiles.

Agriculture↗

DOE OSTI2022

Continuous conditional generative adversarial networks for data-driven solutions of poroelasticity with heterogeneous material properties

Machine learning-based data-driven modeling can allow computationally efficient time-dependent solutions of PDEs, such as those that describe subsurface multiphysical problems. In this work, our previous approach (Kadeethum et al., 2021d) of conditional generative adversarial networks (cGAN) developed for the solution of steady-state problems involving highly heterogeneous material properties is extended to time-dependent problems by adopting the concept of continuous cGAN (CcGAN). The CcGAN that can condition continuous variables is developed to incorporate the time domain through either element-wise addition or conditional batch normalization. Moreover, this framework can handle training data that contain different timestamps and then predict timestamps that do not exist in the training data. As a numerical example, the transient response of the coupled poroelastic process is studied in two different permeability fields: Zinn & Harvey transformation and a bimodal transformation. The proposed CcGAN uses heterogeneous permeability fields as input parameters while pressure and displacement fields over time are model output. Our results show that the model provides sufficient accuracy with computational speed-up. This robust framework will enable us to perform real-time reservoir management and robust uncertainty quantification in poroelastic problems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Autonomous continuous flow reactor synthesis for scalable atom-precision

With new instrumentation design, robotics, and in-operando hyphenated analytical tool automation, the intelligent discovery of synthesis pathways is becoming feasible. It can potentially bridge the gap for the scale-up of new materials. In this article, we review current progress and describe a new system that uses an autonomous continuous flow chemistry framework to translate high-quality lead molecules and materials to quantities that can meet scalability demands. At the core is a continuous flow synthesis platform that can design its viable synthesis pathway to a particular molecule or material and then autonomously carry it out. This is realized by integrating: (1) A workflow/architecture for multimode chemical/materials characterization in-line. The in-line characterization modes are NMR, ESR, IR, Raman, UV-Vis, GC-MS, and HPLC, along with ex-situ modes for X-Ray and neutron scattering; (2) Integration for feedback/analysis/data storage of the control variables; (3) A core software stack that includes deep learning and reinforcement learning alongside quantum chemistry and molecular dynamics; (4) On-demand compute architectures that parse calculations to compute resources needed which include light-weight edge, mid-level edge (NVIDA DGX-2), and high-performance computing. We demonstrate preliminary results on how this autonomous reactor system can enhance our ability to deliver deuterated materials, copolymers, and site-substituted molecules.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Continuous recovery of phosphoric acid and Rare-Earths containing particles from phosphoric acid sludge using a decanter centrifuge

Recovery of rare earth elements (REEs) from various industrial and natural streams currently draws significant attention in efforts to meet the demands of the manufacturing industry. Among many industrial byproducts and waste streams, phosphoric acid sludge could be one of the most economically feasible resources for the recovery of REEs because solid particles in the sludge contain relatively concentrated REEs, up to 3,000 ppm, while the liquid component of the sludge is valuable phosphoric acid (P 2 O 5 ) that can be recovered and returned to the main product. Due to high viscosity and large solids content (e.g., 30–40 %), however, this byproduct stream requires multistep separation and purification processes. In this study, a single-step process involving a continuous-flow decanter centrifuge (CFDC) was employed to investigate its feasibility for continuous solid/liquid separation from real phosphoric acid sludge. High centrifugal forces generated from up to 1500 G gravity acceleration separate solid particles from the sludge, generating a liquid-rich stream and a solids-rich stream at the exit of the CFDC. A single pass of phosphoric-acid sludge through the CFDC yielded 95 % liquid recovery and 90 % recovery of REEs-containing solids from 20 to 34 wt% solids-containing sludge. Finally, a reduced order model developed for the CFDC operation showed good agreement with experimental data, and preliminary technoeconomic analysis revealed potential process feasibility.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Emerging continuous SiC fibers for high-temperature applications

Silicon carbide (SiC) fibers are responsible for the ultimate strength and toughness of SiC-fiber reinforced composites in harsh environments. The development of a new generation of continuous SiC fibers continues to advance the mechanical properties of composite materials. Tyranno™ SA4 fiber was recently released as a successor of Tyranno™ SA3 fiber. Laser-driven chemical vapor deposition (LCVD) has been adopted as an alternative fiber processing route to synthesizing high-strength SiC fiber with tailorable small diameters and chemical compositions. Both Tyranno™ SA4 and laser-driven CVD fibers show very high tensile strength, about 4 GPa in the as-fabricated condition. The degradation of thermal stability and strength due to annealing in an inert environment were similar for Tyranno™ SA3 and SA4 fibers because of their similar carbon-rich, crystalline microstructure. Silicon-rich fibers produced by LCVD possessed heterogeneous crystallinity, which was attributed to laser power distribution and showed microstructural instability at 1500 °C and above. Finally, the new SiC fibers demonstrated an increase in as-fabricated strength but faced the same challenges in environmental resistance as the traditional SiC fibers do.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Simulated moving bed-inspired method for continuous adsorptive denitrogenation of model fuel

Efficient, continuous routes for removing nitrogen-containing compounds from hydrothermal liquefaction-derived synthetic aviation fuel are needed to enable direct blending with conventional jet fuels. Here, we report a simulated moving bed-inspired process for adsorptive denitrogenation of a model fuel. Unlike conventional simulated moving bed systems, which are designed for sharp separations between similar solutes, this approach was run deliberately outside the classical separation region so that both pyridine and indole were removed together from the hydrocarbon stream. Alcohol solvents were used to regenerate the silica adsorbent, maintaining performance over extended operation and avoiding the downtime and energy demand associated with calcination. Under these conditions, the system demonstrates removal of more than 98% of nitrogen while cutting solvent use by 28% compared to batch operation. Classical modeling tools predicted column concentration profiles even in this nontraditional regime, suggesting a straightforward path to scaling. Together, these results motivate solvent-efficient, continuous denitrogenation strategies that could be integrated with biorefinery processes.

Adsorption↗

DOE OSTI2020

Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Light-weight construction, design freedom, integration of functions, and compelling cost element are desired by Original Equipment Manufacturers (OEMs) and their suppliers. The emergence of overmolding of continuous-discontinuous reinforcement enables design freedom and ability to tailor stiffness, strength, and damage tolerance for structural applications. In this work, long fiber thermoplastics (LFT) are overmolded with continuous fiber-reinforced thermoplastic (CFRTP) tape are combined using extrusion compression molding process to evaluate the structural performance. The CFRTP tape overmolded LFT samples were characterized using nondestructive and destructive techniques to track fiber alignment, fiber distribution, manufacturing defects, interfacial bonding of the tape – LFT and effect of CFRTP tape on LFT. Mode 1 fracture toughness, G 1c for tape overmolded LFT was higher by 25–30% compared to literature reported G 1c . This response was attributed to excellent fiber distribution, good fiber wetting, and absence of voids at the interface. Three-point bend test indicated that CFRTP tape overmolded LFT composites were better able to resist damage under the bending load compared to constituent LFT composite. Flexural strength of the overmolded composite was higher by 119–142%, and modulus higher by 77–65% compared to constituent LFT composite. Simulated flexural results accurately represents the mechanical behavior of composites. Here, the penetration energy of tape overmolded LFT composites determined by LVI test was in the range of 27.66–30.15 J, which is significantly higher than constituent LFT composite, 7.76 J. CFRTP tape overmolded LFT composite exhibits progressive fiber fracture, matrix cracking, and interfacial debonding failure, whereas, constituent LFT composite showed catastrophic fiber fracture.

42 ENGINEERING↗

DOE OSTI2021

Characterization data of an (AlFeNiTiVZr) 1-x Cr x multi-principal element alloy continuous composition spread library

The data provided in this article is related to the research article entitled “Phase stabilization and oxidation of a continuous composition spread multi-principal element (AlFeNiTiVZr) 1-x Cr x alloy”. This data article describes the high-throughput synthesis and characterization processes of an (AlFeNiTiVZr) 1-x Cr x alloy system. Continuous composition spread (CCS) thin-film libraries were synthesized by co-depositing an AlFeNiTiVZr metal alloy target and Cr target via magnetron sputtering. Post-processing was performed on the sample libraries with a vacuum anneal at 873 K and an air anneal at 873 K. Compositional data was determined via WDS in order to verify parameters provided by an in-house sputter model. Crystallographic data was captured via synchrotron diffraction and diffractograms were compared as a function of the change in Cr concentration. These measurements were taken in order to observe phase behavior after oxidation throughout the composition library. Furthermore, vibrational spectrographic data is provided of the oxidized library to show surface speciation along the composition gradient of the alloy system. The structural and oxidative behavior of the (AlFeNiTiVZr) 1-x Cr x alloy can be analysed using the data provided in this article. Additionally, this characterization dataset can be utilized in machine learning algorithms for determining important features and parameters for future hypothesis generation of functional multi-principal element alloys (MPEAs).

36 MATERIALS SCIENCE↗