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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Carbon-Binder Optimization for Lithium-Ion Battery Extreme Fast Charge

Battery performance is strongly correlated with electrode microstructure and weight loading of the electrode components. Among them are the carbon-black and binder additives that enhance effective conductivity and provide mechanical integrity. However, these both reduce effective ionic transport in the electrolyte phase and reduce energy density. Therefore, an optimal additive loading is required to maximize performance, especially for fast charging where ionic transport is essential. Such optimization analysis is however challenging due to the nanoscale imaging limitations that prevent characterizing this additive phase and thus quantifying its impact on performance. Herein, an additive-phase generation algorithm has been developed to remedy this limitation and identify percolation threshold used to define a minimal additive loading. Improved ionic transport coefficients from reducing additive loading has been then quantified through homogenization calculation, macroscale model fitting, and experimental symmetric cell measurement, with good agreement between the methods. Rate capability test demonstrates capacity improvement at fast charge at the beginning of life, from 37% to 55%, respectively for high and low additive loading during 6C CC charging, in agreement with macroscale model, and attributed to a combination of lower cathode impedance, reduced electrode tortuosity and cathode thickness.

carbon-binder additives↗
DOE OSTI2021

Experimental Investigation of Concrete Fatigue in Axial Compression

The use of concrete in fatigue critical structures, such as wind turbine towers, has necessitated the replacement of simplistic (and therefore insufficient) fatigue design recommendations with more accurate and advanced fatigue models that can consider a greater complexity of stress states and materials. As the first part of a multistage test series, an experimental investigation was conducted to determine the fatigue life of concrete subjected to axial compressive fatigue loading, focusing on the relatively high-cycle fatigue domain. Here, a wide range of values for maximum stress levels and stress ratios were considered. The experimental results were compared against existing predictive models, and the most applicable model was identified. Concrete strain and stiffness behavior during fatigue loading were also investigated and reported. Based on the observed behavior, a hypothesis for identifying the impending occurrence of fatigue failure, based on the monotonic stress-strain curve, is examined.

17 WIND ENERGY↗
DOE OSTI2015

Evaluation of Additive Manufacturing for Composite Part Molds

The ORNL Manufacturing Demonstration Facility (MDF) collaborated with Tru-Design to test the quality and durability of molds used for making fiber reinforced composites using additive manufacturing. The partners developed surface treatment techniques including epoxy coatings and machining to improve the quality of the surface finish. Test samples made using the printed and surface finished molds demonstrated life spans suitable for one-of-a-kind and low-volume applications, meeting the project objective.

36 MATERIALS SCIENCE↗
DOE OSTI2017

HLW Flexible jumper materials compatibility evaluation

H-Tank Farm Engineering tasked SRNL/Materials Science & Technology (MS&T) to evaluate the compatibility of Goodyear Viper® chemical transfer hose with HLW solutions. The hose is proposed as a flexible Safety Class jumper for up to six months service. SRNL/MS&T performed various tests to evaluate the effects of radiation, high pH chemistry and elevated temperature on the hose, particularly the inner liner. Test results suggest an upper dose limit of 50 Mrad for the hose. Room temperature burst pressure values at 50 Mrad are estimated at 600- 800 psi, providing a safety factor of 4.0-5.3X over the anticipated operating pressure of 150 psi and a safety factor of 3.0-4.0X over the working pressure of the hose (200 psi), independent of temperature effects. Radiation effects are minimal at doses less than 10 Mrad. Doses greater than 50 Mrad may be allowed, depending on operating conditions and required safety factors, but cannot be recommended at this time. At 250 Mrad, burst pressure values are reduced to the hose working pressure. At 300 Mrad, burst pressures are below 150 psi. At a bounding continuous dose rate of 57,870 rad/hr, the 50 Mrad dose limit is reached within 1.2 months. Actual dose rates may be lower, particularly during non-transfer periods. Refined dose calculations are therefore recommended to justify longer service. This report details the tests performed and interpretation of the results. Recommendations for shelf-life/storage, component quality verification, and post-service examination are provided.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Low Temperature Process Utilizing Nano-Engineered Catalyst for Olefin Production from Coal Derived Flue Gas (Final Report)

Southern Research [SR] demonstrated a new process using rationally designed nano-engineered catalysts to produce high yield of light olefins by using CO 2 from coal-fired flue gas. Multiple catalysts and process conditions, designed systematically were tested to find the optimum conditions for which maximum yield could be achieved. Southern research team has specifically targeted CO 2 -rich and marginally purified coal-fired flue gas streams as feedstock for this process. Systematic reaction analysis in presence of different key flue gas components (e.g., O 2 , SO x , NO x ) were used for testing catalyst stability and performance level. A techno-economic and life cycle assessment based on the results revealed various aspects of commercialization of this process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Low Temperature Process Utilizing Nano-Engineered Catalyst for Olefin Production from Coal Derived Flue Gas

Southern Research [SR] demonstrated a new process using rationally designed nano-engineered catalysts to produce high yield of light olefins by using CO 2 from coal-fired flue gas. Multiple catalysts and process conditions, designed systematically were tested to find the optimum conditions for which maximum yield could be achieved. Southern research team has specifically targeted CO 2 -rich and marginally purified coal-fired flue gas streams as feedstock for this process. Systematic reaction analysis in presence of different key flue gas components (e.g., O 2 , SO x , NO x ) were used for testing catalyst stability and performance level. A techno-economic and life cycle assessment based on the results revealed various aspects of commercialization of this process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Creep and Creep Fracture Modeling with Surrogate Creep Models and the Extended Finite Element Method

Alloy components in advanced nuclear reactors will be subjected to environmental conditions that could include high temperatures, irradiation, and exposure to corrosive salts. These conditions could lead to the formation of crack-like defects, which could grow over time in a mechanism known as creep crack growth (CCG). Predicting growth rates of these defects is important for assessing the safe operating life of advanced reactors. This project documents progress toward developing and testing next-generation data-driven constitutive models for deformation creep. It also documents the application of the extended finite element method in conjunction with surrogate creep models to predict CCG parameters under a variety of conditions. These important incremental developments contribute to the longer-term objective of developing microstructure-aware constitutive models that can be used for predicting creep deformation and CCG at the component scale with improved accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Operation at Reduced Atmospheric Pressure and Concept of Reliability Redundancy for Optimized Design of Insulation Systems

Electrified transportation is calling for insulation design criteria that is adequate to provide elevated levels of power density, power dynamics and reliability. Increasing voltage levels are expected to cause accelerated intrinsic and extrinsic aging effects which will not be easily predictable at the design stage due to a lack of suitable modeling. Designing reliable insulation systems would require finding solutions able to control accelerated aging due to an unpredictable increase of intrinsic stresses and the onset of extrinsic stresses as partial discharges. This paper proposes the concept of reliability redundancy for the insulation design of aerospace electrical asset components, which is also validated at lower-than-standard atmospheric pressure. The principle is that extrinsic-aging-free design might be achieved upon determining the aging stress or abnormal service stresses distribution and being sure that aging will not generate conditions that can incept extrinsic aging (partial discharges) during operation life. However, such information is never, in practice, fully available to insulation system designers. Hence, especially in critical applications such as electrified aircraft, aerospace, and combat ships a further level of reliability should be added to a partial-discharge-free design, which can consist of the use of corona-resistant materials and/or of life models able to consider the accelerated aging effect of partial discharges (or any other type of extrinsic-accelerated aging factor). Innovative life modeling considering both extrinsic and intrinsic aging stresses, insulating material testing to estimate model parameters, and a metric for quantifying the extent of corona (or partial discharge) resistance can lead to establishing feasibility and limit conditions for optimized or fully reliability-redundant design. It is shown in the paper that if an extrinsic-aging-free design is not feasible, and it is therefore replaced by a redundant design, a further level of reliability redundancy can be provided by effective condition monitoring plans.

Montanari, Gian Carlo↗
DOE OSTI2020

BACKFLIP Project: Determination of BACKsheet Material Properties: A Comparison of Market-Benchmark Technologies to Novel Non-Fluoro-Based Co-Extruded Backsheet Materials and Their Correlation and Impact on PV Module Degradation Rates

Quantifying degradation rate of backsheets will help procuring materials for 30+ years. Today most backsheets on the market have a laminated PET core; polyolefin materials may provide better properties for backsheets (barrier to water, mechanical properties through UV and hydrolytic environments, etc.). End-of-life regulations may require fluorine-free backsheet products in future global markets. Parametrized equation predicting the service life of backsheets, and validated by both lab and outdoor extensive testing. Technical and commercial confidence to the entire value chain: from backsheet and module manufacturers to the downstream community (IPP, banks, developers) that materials of higher quality can help reduce finance costs, therefore driving down LCOE. A fast track PV module market adaptation for novel high-quality materials, such as co-extruded polyolefin-core backsheets, by obtaining unbiased durability data.

14 SOLAR ENERGY↗
DOE OSTI2026

Coalition for Community-Supported Affordable Geothermal Energy Systems (C2SAGES)

The C2SAGES project evaluated the feasibility of a community geothermal system for the planned Windy Ridge affordable housing development in Hinesburg, Vermont. Led by GTI Energy with Vermont Gas Systems, LN Consulting, NREL, and Frontier Energy, the work assessed technical design, energy performance, costs, business models, community engagement, maintenance, workforce development, and permitting. The proposed system was designed to serve 100% of the development’s heating, cooling, and domestic hot water loads. Compared with a baseline using air-source heat pumps and natural gas water heating, the geothermal system was estimated to reduce HVAC and domestic hot water energy use by about 45% to 48%, lower operating and maintenance costs, and reduce 30-year life-cycle costs by 37% for Phase 1 and 10% for Phase 2. Technical testing and modeling indicated that the Windy Ridge site is suitable for a community-scale geothermal system. The project also developed borehole field layouts, piping concepts, pump house designs, controls, maintenance plans, and supporting engineering drawings. The business model analysis found that first cost, ownership structure, and customer affordability remain major deployment challenges. Utility-led maintenance and operation were viewed favorably, but traditional utility cost-recovery models may require subsidy or revised financing structures to be practical for affordable housing. Community engagement highlighted the need for clear public education, transparent financing, reliable long-term maintenance, trained technicians, and the potential to pair geothermal systems with weatherization. Overall, the report concludes that community geothermal is technically feasible and offers meaningful energy, emissions, and life-cycle cost benefits, but broader deployment will depend on workable financing models and workforce readiness.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Modeling-Based Design and Optimization of a Gradient Composite Transition Joint

An innovative additively manufactured gradient composite transition joint (AM-GCTJ) has been designed to join dissimilar metals, to address the pressing issue of premature failure observed in conventional dissimilar metal welds (DMWs) when subjected to increased cyclic operating conditions of fossil fuel power plants. The transition design, guided by computational modeling, developed a gradient composite material distribution, facilitating a smooth transition in material volume fraction and physical properties between different alloys. This innovative design seeks to alleviate structural challenges arising from distinct material properties, including high thermal stress and potential cracking issues resulting from the thermal expansion mismatch typically observed in conventional DMWs. In this study, we investigated the creep properties of transition joints comprising Grade 91 steel and 304 stainless steel through a combination of simulations and creep testing experiments. The implementation of a gradient composite design in the plate transition joint resulted in a significant enhancement of creep resistance when compared to the baseline conventional DMW. For instance, the creep rupture life of the transition joint was improved by > 400% in a wide range of temperature and stress testing conditions. Meanwhile, the failure location shifted to the base material of Grade 91 steel. Such enhancement can be primarily attributed to the strong mechanical constraint facilitated by the gradient composite design, which effectively reduced the stresses on the less creep-resistant alloy in the transition zone. Beyond examining plate joints, it is crucial to assess the deformation response of tubular transition joints under pressure loading and transient temperature conditions to substantiate and demonstrate the effectiveness of the design. The simulation results affirm that the tubular transition joint demonstrates superior resistance compared to its counterpart DMW when subjected to multiaxial stresses in tubular structures. In addition, optimization of the transition joint’s geometry dimensions has been conducted to diminish the accumulated deformation and enhance the service life. Lastly, the scalability and potential of the innovative transition joints for large-diameter pipe applications are addressed.

Zhang, Wei↗
DOE OSTI2015

Status Report - Cane Fiberboard Properties And Degradation Rates For Storage Of The 9975 Shipping Package In KAC

Thermal, mechanical and physical properties have been measured on cane fiberboard samples following accelerated aging for up to approximately 10 years. The aging environments have included elevated temperature < 250 ºF (the maximum allowed service temperature for fiberboard in 9975 packages) and elevated humidity. The results from this testing have been analyzed, and aging models fit to the data. Correlations relating several properties (thermal conductivity, energy absorption, weight, dimensions and density) to their rate of change in potential storage environments have been developed. Combined with an estimate of the actual conditions the fiberboard experiences in KAC, these models allow development of service life predictions.

42 ENGINEERING↗
DOE OSTI2018

Implementation of ANL’s Mechanics Based Evolutionary Fatigue Modeling Through ABAQUS-WARP3D Based High-Performance Computing Framework

This report presents an update on the environmental fatigue research that is being conducted at Argonne National Laboratory in support of the Department of Energy’s Light Water Reactor Sustainability (LWRS) program. Argonne is developing a fully mechanistic fatigue evaluation approach without using empirical fatigue (S~N) curves. This approach is based on the fundamental concept of the time evolution of progressive fatigue damage rather than on the conventional S~N curve approaches using end-of-life data. In FY 2017, we performed extensive validation of this approach with respect to fatigue test data for 316 stainless steel [1]. This validation was performed for different loading cases, including constant, variable, and random amplitude. In the present FY 2018 semi-annual report, we present the further advances of Argonne’s environmental fatigue research work in the context for more practical applications. In this report, we discuss a methodology for fully mechanistic (i.e., not using S~N curves) fatigue life evaluation of reactor components subjected to realistic loading cycles, namely, design-basis loading cycles. The loading cycles include plant heat-up, full-power, and cool-down operations. As a test case, we considered a typical pressurized water reactor surge line, which is made of 316 SS. To perform the fatigue simulation for thousands of fatigue cycles in a computationally cost effective way, we modified our previous desktop-based finite element (FE) modeling approach to work in a high-performance computing (HPC) framework. For the HPC implementation, we developed a hybrid framework based on commercial FE software (ABAQUS), open-source FE software (WARP3D), and Argonne-developed evolutionary cyclic-plasticity modeling methods. We validated this HPC-based cycle-by-cycle damage model for the entire fatigue life of a Pressurized Water Reactor (PWR) surge line (SL) pipe with respect to assumed loading cycles. The simulated fatigue life was found to be 5855 cycles, which is 85% accurate as compared to the corresponding small-specimen-based experimental fatigue life (6914 cycles). Also, the simulated stress history captures the cyclic hardening and softening behavior of the material for entire fatigue cycles. The FE simulation of the PWR SL pipe was conducted in a reasonable time of 12.5 days. These results show the promise that a fully mechanistic (not using S~N curves) fatigue life evaluation of a safety-critical nuclear reactor component (or even other safety critical components like those in aircraft, aero-engines, etc.) is possible. We anticipate that this type of methodology will drastically reduce the uncertainly associated with conventional fatigue life estimates based on empirical S~N curves. We also proposed an FE model that is based on a hybrid full-component and single-element approach and that can readily be used by industry if HPC resources are not available. In this approach, a single-cycle FE simulation has to be performed first for the required loading cycle. Then, the resulting strain/stress profile at the hotspot (highest strain/stress location) is used as input strain/stress loading to the single-element FE model. The single-element FE model is run under multiple fatigue cycles as long as the failure criteria are achieved. The cycle number at failure gives the fatigue life of the component in question. This cost-effective framework does not require expensive HPC hardware and can be performed in a reasonable time by using a desktop computer. We demonstrated this approach with respect to PWR SL fatigue evaluation under two realistic design-basis loading cycles (simple and detailed). The associated results were validated with respect to test data obtained through fatigue testing of uniaxial specimens under the in-air condition at 300 °C. The approach is in the development stage and requires further improvement and validation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Status Report - Softwood Fiberboard Properties And Degradation Rates For Storage Of The 9975 Shipping Package In KAC

Thermal, mechanical and physical properties have been measured on softwood fiberboard samples following accelerated aging for up to approximately 7 years. The aging environments have included elevated temperature < 250 ºF (the maximum allowed service temperature for fiberboard in 9975 packages) and elevated humidity. The results from this testing have been analyzed, and preliminary aging models fit to the data. Correlations relating several properties (thermal conductivity, energy absorption, weight, dimensions and density) to their rate of change in potential storage environments have been developed. Combined with acceptance criteria and an estimate of the actual conditions the fiberboard experiences in KAC, these models allow development of service life predictions.

42 ENGINEERING↗
DOE OSTI2015

Validation of a method for in vivo 3D dose reconstruction for IMRT and VMAT treatments using on-treatment EPID images and a model-based forward-calculation algorithm

Purpose: Radiation treatments are trending toward delivering higher doses per fraction under stereotactic radiosurgery and hypofractionated treatment regimens. There is a need for accurate 3D in vivo patient dose verification using electronic portal imaging device (EPID) measurements. This work presents a model-based technique to compute full three-dimensional patient dose reconstructed from on-treatment EPID portal images (i.e., transmission images). Methods: EPID dose is converted to incident fluence entering the patient using a series of steps which include converting measured EPID dose to fluence at the detector plane and then back-projecting the primary source component of the EPID fluence upstream of the patient. Incident fluence is then recombined with predicted extra-focal fluence and used to calculate 3D patient dose via a collapsed-cone convolution method. This method is implemented in an iterative manner, although in practice it provides accurate results in a single iteration. The robustness of the dose reconstruction technique is demonstrated with several simple slab phantom and nine anthropomorphic phantom cases. Prostate, head and neck, and lung treatments are all included as well as a range of delivery techniques including VMAT and dynamic intensity modulated radiation therapy (IMRT). Results: Results indicate that the patient dose reconstruction algorithm compares well with treatment planning system computed doses for controlled test situations. For simple phantom and square field tests, agreement was excellent with a 2%/2 mm 3D chi pass rate ≥98.9%. On anthropomorphic phantoms, the 2%/2 mm 3D chi pass rates ranged from 79.9% to 99.9% in the planning target volume (PTV) region and 96.5% to 100% in the low dose region (>20% of prescription, excluding PTV and skin build-up region). Conclusions: An algorithm to reconstruct delivered patient 3D doses from EPID exit dosimetry measurements was presented. The method was applied to phantom and patient data sets, as well as for dynamic IMRT and VMAT delivery techniques. Results indicate that the EPID dose reconstruction algorithm presented in this work is suitable for clinical implementation.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

Fatigue modeling for carbon/epoxy unidirectional composites under various stress ratios considering size effects

In this work, fatigue tests for unidirectional (UD) CFRP composite specimens of various sizes are conducted under different stress ratios. The results show that the specimen size has considerable influence on the transverse tension-tension fatigue performance of UD laminates. The underlying fatigue mechanisms are also investigated through SEM observations. Moreover, a fatigue life prediction method considering size effects is presented, and a good correlation is observed between the prediction and the test data. Lastly, to allow for an evaluation of the effects of mean stress, constant fatigue life diagrams for 0°, 10°, and 90° UD composites are established based on four-segment anisomorphic model.

36 MATERIALS SCIENCE↗
DOE OSTI2016

SU-F-SPS-01: Accuracy of the Small Field Dosimetry Using Acuros XB and AAA Dose Calculation Algorithms of Eclipse Treatment Planning System Within and Beyond Heterogeneous Media for Trubeam 2.0 Unit

Purpose: In this study, the comparison of dosimetric accuracy of Acuros XB and AAA algorithms were investigated for small radiation fields incident on homogeneous and heterogeneous geometries Methods: Small open fields of Truebeam 2.0 unit (1×1, 2×2, 3×3, 4×4 fields) were used for this study. The fields were incident on homogeneous phantom and in house phantom containing lung, air, and bone inhomogeneities. Using the same film batch, the net OD to dose calibration curve was obtaine dusing Trubeam 2.0 for 6 MV, 6 FFF, 10 MV, 10 FFF, 15 MV energies by delivering 0- 800 cGy. Films were scanned 48 hours after irradiation using an Epson 1000XL flatbed scanner. The dosimetric accuracy of Acuros XB and AAA algorithms in the presence of the inhomogeneities was compared against EBT3 film dosimetry Results: Open field tests in a homogeneous phantom showed good agreement betweent wo algorithms and measurement. For Acuros XB, minimum gamma analysis passin grates between measured and calculated dose distributions were 99.3% and 98.1% for homogeneousand inhomogeneous fields in thecase of lung and bone respectively. For AAA, minimum gamma analysis passingrates were 99.1% and 96.5% for homogeneous and inhomogeneous fields respectively for all used energies and field sizes.In the case of the air heterogeneity, the differences were larger for both calculations algorithms. Over all, when compared to measurement, theAcuros XB had beter agreement than AAA. Conclusion: The Acuros XB calculation algorithm in the TPS is an improvemen tover theexisting AAA algorithm. Dose discrepancies were observed for in the presence of air inhomogeneities.

60 APPLIED LIFE SCIENCES↗