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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

CO 2 Absorption and Magnesium Carbonate Precipitation in MgCl 2 –NH 3 –NH 4 Cl Solutions: Implications for Carbon Capture and Storage

CO 2 absorption and carbonate precipitation are the two core processes controlling the reaction rate and path of CO 2 mineral sequestration. Whereas previous studies have focused on testing reactive crystallization and precipitation kinetics, much less attention has been paid to absorption, the key process determining the removal efficiency of CO 2 . In this study, adopting a novel wetted wall column reactor, we systematically explore the rates and mechanisms of carbon transformation from CO 2 gas to carbonates in MgCl 2 –NH 3 –NH 4 Cl solutions. We find that reactive diffusion in liquid film of the wetted wall column is the rate-limiting step of CO 2 absorption when proceeding chiefly through interactions between CO 2 (aq) and NH 3 (aq). We further quantified the reaction kinetic constant of the CO 2 –NH 3 reaction. Our results indicate that higher initial concentration of NH 4 Cl ( ≥2mol∙L -1 ) leads to the precipitation of roguinite [(NH 4 ) 2 Mg(CO 3 ) 2 ∙4H 2 O], while nesquehonite appears to be the dominant Mg-carbonate without NH 4 Cl addition. We also noticed dypingite formation via phase transformation in hot water. This study provides new insight into the reaction kinetics of CO 2 mineral carbonation that indicates the potential of this technique for future application to industrial-scale CO 2 sequestration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Effect of the Soldering Atmosphere on the Wettability Between Sn4.0Ag0.5Cu (in wt.%) Lead-Free Solder Paste and Various Substrates

The “degree of wetting,” which is related to the contact angle (θ) between the molten solder and the substrate, is a useful parameter on the solderability process control. The contact angle, however, is strongly dependent on the type of substrate surface finish and used atmosphere (inert or non-inert). Furthermore, the surface tension, being an important parameter on the solderability process and performance, can also be achieved if the contact angle is known. In this study, the SAC405 [Sn4.0Ag0.5Cu (in wt.%)] solder paste contact angle was measured, by the “sessile drop” method, as a function of the temperature, surface pad finish and used atmosphere. The results are discussed, and the contact angles obtained for the different conditions are compared and discussed. Then, the surface tension (experimental) was obtained from the measured contact angle and compared with the obtained by using computation models (theoretical). The experiments performed in high vacuum conditions, i.e., low oxygen content, over a temperature range, allowed the evaluation and understanding of the surface oxides layers role on the solder wettability. The present study shows that in the soldering process, even in an inert atmosphere, usually used in industry, occurs the formation of superficial oxides, over the liquid solder and/or at the pad surfaces, that strongly affects the solder paste wettability, specially with Sn and OSP (organic solderability preservative) finishing. Differences in contact angle of ≥ 10° were determined between the two types of used atmospheres. The experimental surface tension and theoretical surface tension obtained, for the NiAu substrate type, present good correlation. The lower contact angle values were obtained for the NiAu and OSP finish types, independently of the atmosphere type.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Annealing to Mitigate Pitting in Electropolished Niobium Coupons and SRF Cavities

Ongoing studies at Fermilab investigate whether dislocations and other factors instigate pitting during cavity electropolishing (EP), despite careful processing controls and the inherent leveling mechanism of EP itself. Here, cold-worked niobium coupons, which exhibited increased tendencies for pitting in our past study, were annealed in a high vacuum furnace and subsequently processed by EP. Laser confocal scanning microscopy and special defect counting algorithms were used to assess the population of pits formed. Hardness measurements indicated that annealing for 2 hours at 800 C produced recovery, whereas annealing for 12 hours at 600 C did not, as is consistent with known changes for cavities annealed in a similar way. The 800 C anneal was effective in some cases but not others, and we discuss reasons why tendencies for pitting remain. We discuss implications for cavities and continued work to understand pitting.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Control of formation of viscoelastic droplets and distribution of nano-inclusions in functional deposition for lithium–sulfur batteries

The electrospray process produces micro/nanodroplets for various applications such as thin and uniform coatings, drug carriers and mass spectrometry. In this paper, we study the spray processes of viscoelastic jets using simulations and experiments. In discretized modeling, the jet is perturbed with axisymmetric instability and the growth of this instability causes the jet to break into droplets. For the experiments, a solution of polyvinyl alcohol in water is sprayed and is visualized using a high-speed camera. The droplet size distribution is studied from simulations with experiments for three spray cases: electrospray, air spray, and air-controlled electrospray. Our simulations and experiments reveal that the electric field is effective in reducing the droplet size, while air flow offers more jet break-ups and thus a larger number of droplets. As a result, air-controlled electrospray where these two driving forces are synergistically combined leads to a larger number of smaller droplets than electrospray or air spray. As a result, we applied three spray processes to obtain a deposition of sulfur/mesoporous carbon/graphene/polymer binder composites as a lithium sulfur battery cathode and demonstrated that air-controlled electrospray leads to a higher capacity and rate capability than other processes, exhibiting 800 mA h g –1 at 0.5C and 600 mA h g –1 at 2C.

25 ENERGY STORAGE↗
DOE OSTI2013

Theoretical and experimental investigation of evanescent-wave absorption sensors for extreme temperature applications

Recently, significant developments in evanescent wave absorption sensors have been demonstrated for high temperature sensing applications based upon the optical responses of advanced thin film materials. We will demonstrate how such sensors can be utilized in a mode that allows for chemical or temperature sensing starting from basic theoretical considerations. We will also present experimental high temperature sensing results for fabricated sensors. Potential applications of the sensors to be discussed include a range of high temperature systems relevant for fossil energy and combustion monitoring such as industrial combustors or reaction vessels, solid oxide fuel cells, and gas turbines. In these applications, even a small increase in operating efficiency realized via careful observation of in-process parameters and implementation of real-time process controls can result in dramatic savings across the energy industry, illustrating the necessity of pursuing such techniques. It is hoped that sensors of the type described here will allow for unprecedented measurement-access to processes which present challenging high-temperature and chemically reactive environments.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Phase-field predictions of the influence of cooling rates during AM on the Evolution of Microstructures in Nickel-Based Single Crystal Superalloys

Additive manufacturing of single crystals made of Ni-based superalloys offers major cost savings for gas turbine engines with the inclusion of internal cooling channels. However, the lack of understanding of the effect of transient thermal conditions on solidification grain structure during additive manufacturing hinders the potential for process control to maintain the single crystal quality. The use of high-fidelity simulations through high performance computing to predict the evolution of the solidification microstructure will enhance the abilities to tailor the microstructures through process optimization. Phase field simulations are used to determine the effect local thermal conditions and defects on the stability of the solidification morphology, specifically with respect to the onset of columnar-to-equiaxed transition that results in the loss of the single crystal. The results are expected to be instrumental for developing future surrogate models to speed up the integration of design and manufacturing of turbine blades under the harsh in-service conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Next-Generation Ecosystem Experiments–Tropics Flyer

Tropical forests cycle more carbon and water than any other ecosystem, and they play critical roles in determining Earth’s energy balance. Additionally, intact tropical forests are estimated to be Earth’s largest carbon sink, yet the processes controlling tropical forest carbon cycling are not well established. Understanding of carbon and related water and energy exchanges between tropical forests and the atmosphere lags that of other ecosystems, and poor model representation of these processes is the most significant source of terrestrial uncertainty in climate projections. To address these challenges, the Terrestrial Ecosystem Science (TES) program within the Department of Energy’s (DOE) Office of Biological and Environmental Research (BER) is supporting a next-generation ecosystem experiments project in the tropics (NGEE–Tropics).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Designing an Intrusion Detection for an Adjustable Speed Drive System Controlling a Critical Process

In this article, we address the cyber-security problem of industrial control systems (ICSs) when their sensor measurements may be compromised due to an attacker who has intercepted those measurements via a network. We introduce a general-purpose method “Dynamic Watermarking (DW)” to detect potential cyber-intrusions on speed sensor measurements within industrial control systems, which deploy an adjustable speed drive (ASD) to control a critical process. The DW method is injecting a random private low-amplitude signal with a zero mean Gaussian distribution, “watermark”, into one of the input phase voltages powering the ASD system. The watermark signal propagates through the system including pulse width modulation (PWM) power conversion stage and motor, then ultimately appears in the speed sensor measurements. By deploying two statistical DW tests with two proper thresholds, the system can detect potential cyber-intrusions or unobservable cyber-attacks such as replay attacks and false data injection attacks (FDIA). The DW method tested on a laboratory-scale ASD system experimentally to protect the system against cyber-intrusions. This system, powered by a commercial PWM drive operating at 208 V, 3-phase, and 3.7 kW, served as our experimental platform.

42 ENGINEERING↗
DOE OSTI2023

Human Factors for Advanced Reactors

Existing light water reactors in the U.S. are primarily large baseload electricity generating facilities. The concept of operations for these plants remains largely unchanged since the advent of commercial nuclear power—the main control room serves as the hub of plant activities and is staffed with multiple licensed operators who work in tandem under the shift supervisor, and staff such as field workers support the control room remotely. While newer plants have brought the advent of digital human-machine interfaces to replace earlier analog and mechanical instrumentation and controls, much of the control process remains unchanged and manual. It is simply a newer version of legacy concepts. Advanced reactors potentially bring considerable changes to the size, fuel type, automation, and staffing of nuclear power plants, necessitating a fundamental shift not just from analog to digital, but further from human to automation, from onsite to remote, from control to monitoring, and from many to few operators. Despite this multitude of parallel evolutions in reactor designs, many of the vendors developing the next generation of reactors represent smaller research and development enterprises. It is therefore not feasible to address all aspects of plant design at the same time. In particular, the competing design aspects of new reactors present a significant challenge to the development of robust and human factored systems at the plant. As vendors develop new reactor designs, much of the early focus is naturally on the fuel and reactor system technology. Looming behind these early advances is the daunting prospect of first-of-a-kind control concepts that have not yet been developed or validated. A failure to address the human element of reactor design early will lead to missed opportunities. The quickest development process is the replication of existing concepts of operations at legacy plants, even when such systems were long ago surpassed by better human-machine technologies outside the nuclear industry. Conversely, attempting to undertake novel concepts of operations late in the design life cycle of a plant could result in protracted development efforts and delays in licensing and deployment. This does not have to happen, and it is imperative that human factors be considered now, early in the design of new reactors.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Data-driven modeling of power generation for a coal power plant under cycling

Increased penetration of renewables for power generation has negatively impacted the dynamics of conventional fossil fuel-based power plants. The power plants operating on the base load are forced to cycle, to adjust to the fluctuating power demands. This results in an inefficient operation of the coal power plants, which leads up to higher operating losses. To overcome such operational challenge associated with cycling and to develop an optimal process control, this work analyzes a set of models for predicting power generation. Moreover, the power generation is intrinsically affected by the state of the power plant components, and therefore our model development also incorporates additional power plant process variables while forecasting the power generation. We present and compare multiple state-of-the-art forecasting data-driven methods for power generation to determine the most adequate and accurate model. We also develop an interpretable attention-based transformer model to explain the importance of process variables during training and forecasting. The trained deep neural network (DNN) LSTM model has good accuracy in predicting gross power generation under various prediction horizons with/without cycling events and outperforms the other models for long-term forecasting. The DNN memory-based models show significant superiority over other state-of-the-art machine learning models for short, medium and long range predictions. The transformer-based model with attention enhances the selection of historical data for multi-horizon forecasting, and also allows to interpret the significance of internal power plant components on the power generation. This newly gained insights can be used by operation engineers to anticipate and monitor the health of power plant equipment during high cycling periods.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

The three-dimensional morphology of growing dendrites

The processes controlling the morphology of dendrites have been of great interest to a wide range of communities, since they are examples of an out-of-equilibrium pattern forming system, there is a clear connection with battery failure processes, and their morphology sets the properties of many metallic alloys. We determine the three-dimensional morphology of free growing metallic dendrites using a novel X-ray tomographic technique that improves the temporal resolution by more than an order of magnitude compared to conventional techniques. These measurements show that the growth morphology of metallic dendrites is surprisingly different from that seen in model systems, the morphology is not self-similar with distance back from the tip, and that this morphology can have an unexpectedly strong influence on solute segregation in castings. These experiments also provide benchmark data that can be used to validate simulations of free dendritic growth.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Monitoring Based Commissioning: Step-by-Step Approach to Implementation in Chiller Plants

Chilled water systems consume a significant portion of the energy in manufacturing, and inefficient operation could significantly influence utility bills and the environmental footprint of a facility. One way to ensure long-term energy-efficient plant operation is to ensure that chilled water system equipment, such as chillers, cooling towers, and pumps, are running at their best. Periodic operational assessments help to meet efficiency objectives for cooling plants. However, occasional set point and operational changes resulting from short-term fluctuations cause the plant operation to deviate from optimal. These changes accumulate over time, and operational efficiency deteriorates. Significant energy efficiency improvement potential in chilled water systems can be achieved by operational changes alone. Recent developments in information technology and the industrial internet of things data processing ability have overcome traditional problems and given rise to a new paradigm: monitoring-based commissioning (MBCx). Commissioning platforms and fault detection and diagnostics capabilities have evolved over time and presented more sophisticated abilities to efficiently control process cooling plants. The typical architectures of the MBCx process and a detailed approach to implement the process for chilled water systems are presented. A case study highlighting the energy-and cost-savings potential of MBCx systems is also presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Evaluation of Equiatomic CrMnFeCoNiCu System and Subsequent Derivation of a Non-Equiatomic MnFeCoNiCu Alloy

Investigation into non-equiatomic high-entropy alloys has grown in recent years due to questions about the role of entropy stabilization in forming single-phase solid solutions. Non-equiatomic alloys have been shown to retain the outstanding mechanical properties exhibited by their equiatomic counterparts and even improve electrical, thermal, and magnetic properties, albeit with relaxed composition bounds. However, much remains to understand the processing–structure–property relationships in all classes of so-called high-entropy alloys (HEAs). Here, we are motivated by the natural phenomena of crystal growth and equilibrium conditions to introduce a method of HEA development where controlled processing conditions determine the most probable and stable composition. This is demonstrated by cooling an equiatomic CrMnFeCoNiCu alloy from the melt steadily over 3 days (cooling rate ~4 °C/h). The result is an alloy containing large Cr-rich precipitates and an almost Cr-free matrix exhibiting compositions within the MnFeCoNiCu system (with trace amounts of Cr). From this juncture, it is argued that the most stable composition is within the CrMnFeCoNiCu system rather than the CrMnFeCoNi system. With further optimization and evaluation, a unique non-equiatomic alloy, Mn 17 Fe 21 Co 24 Ni 24 Cu 14 , is derived. The alloy solidifies and recrystallizes into a single-phase face-centered cubic (FCC) polycrystal. In addition to possible applications where Invar is currently utilized, this alloy can be used in fundamental studies that contrast its behavior with its equiatomic counterpart and shed light on the development of HEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Probing electronic transport of individual nanostructures with atomic precision

Accessing individual nanostructures with atomic precision is an important process in the bottom-up fabrication and characterization of electronic nanodevices. Local electrical contacts, namely nanoelectrodes, are often fabricated by using top-down lithography and chemical etching techniques. These processes however lack atomic precision and introduce the possibility of contamination. Here, we review recent reports on the application of a field-induced emission process in the fabrication of local contacts onto individual nanowires and nanotubes with atomic spatial precision. In this method, gold nanoislands are deposited onto nanostructures precisely by using a scanning tunneling microscope tip, which provides a clean and controllable process to ensure both electrically conductive and mechanically reliable contacts. The applicability of the technique has been demonstrated in a wide variety of nanostructures, including silicide atomic wires, carbon nanotubes, and copper nanowires. These local contacts bridge the nanostructures and the transport probes, allowing for the measurements of both electrical transport and scanning tunneling microscopy on the same nanostructures in situ. The direct correlation between electronic and transport properties and atomic structures can be explored on individual nanostructures at the unprecedented atomic level.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2012

Friction Stir Spot Welding (FSSW) of Advanced High Strength Steel (AHSS)

Friction stir spot welding (FSSW) is applied to join advanced high strength steels (AHSS): galvannealed dual phase 780 MPa steel (DP780GA), transformation induced plasticity 780 MPa steel (TRIP780), and hot-stamped boron steel (HSBS). A low-cost Si3N4 ceramic tool was developed and used for making welds in this study instead of polycrystalline cubic boron nitride (PCBN) material used in earlier studies. FSSW has the advantages of solid-state, low-temperature process, and the ability of joining dissimilar grade of steels and thicknesses. Two different tool shoulder geometries, concave with smooth surface and convex with spiral pattern, were used in the study. Welds were made by a 2-step displacement control process with weld time of 4, 6, and 10 seconds. Static tensile lap-shear strength achieved 16.4 kN for DP780GA-HSBS and 13.2kN for TRIP780-HSBS, above the spot weld strength requirements by AWS. Nugget pull-out was the failure mode of the joint. The joining mechanism was illustrated from the cross-section micrographs. Microhardness measurement showed hardening in the upper sheet steel (DP780GA or TRIP780) in the weld, but softening of HSBS in the heat-affect zone (HAZ). The study demonstrated the feasibility of making high-strength AHSS spot welds with low-cost tools.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Agent-based Cyber Control Strategy Design for Resilient Control Systems: Concepts, Architecture and Methodologies

The implementation of automated regulatory control has been around since the middle of the last century through analog means. It has allowed engineers to operate the plant more consistently by focusing on overall operations and settings instead of individual monitoring of local instruments (inside and outside of a control room). A similar approach is proposed for cyber security, where current border-protection designs have been inherited from information technology developments that lack consideration of the high-reliability, high consequence nature of industrial control systems. Instead of an independent development, however, an integrated approach is taken to develop a holistic understanding of performance. This performance takes shape inside a multiagent design, which provides a notional context to model highly decentralized and complex industrial process control systems, the nervous system of critical infrastructure. The resulting strategy will provide a framework for researching solutions to security and unrecognized interdependency concerns with industrial control systems.

47 OTHER INSTRUMENTATION↗
DOE OSTI2012

Using a Research Simulator for Validating Control Room Modernization Concepts

The Light Water Reactor Sustainability Program is a research, development, and deployment program sponsored by the United States Department of Energy. The program is operated in close collaboration with industry research and development programs to provide the technical foundations for licensing and managing the long-term, safe, and economical operation of nuclear power plants that are currently in operation. Advanced instrumentation and control (I&C) technologies are needed to support the continued safe and reliable production of power from nuclear energy systems during sustained periods of operation up to and beyond their expected licensed lifetime. This requires that new capabilities to achieve process control be developed and eventually implemented in existing nuclear control rooms. It also requires that approaches be developed and proven to achieve sustainability of I&C systems throughout the period of extended operation. Idaho National Laboratory (INL) is working closely with nuclear utilities to develop technologies and solutions to help ensure the safe life extension of current reactors. One of the main areas of focus is control room modernization. Current analog control rooms are growing obsolete, and it is difficult for utilities to maintain them. Using its reconfigurable control room simulator adapted from a training simulator, INL serves as a neutral test bed for implementing new control room system technologies and assisting in control room modernization efforts across.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Thermodynamic and Kinetic Barriers Limiting Solid-State Reactions Resolved through In Situ Synchrotron Studies of Lithium Halide Salts

Although halide salts such as LiCl and LiBr are routinely used as a source of Li ions during ion exchange reactions, a detailed understanding of the processes controlling the rates of these reactions is presently lacking. Recently, it has been discovered that the rate limiting barriers for ion exchange are commonly associated with these salts rather than the ceramic target of ion exchange, making it important to quantitatively understand of salt processes. Here it is demonstrated that in situ synchrotron studies of ion exchange reactions can be used to precisely quantify the thermodynamic activation energies associated with these solid state reactions in a manner that can be directly compared with predictions from density functional theory (DFT). While the temperature dependence of the LiCl reaction rate is found to be set by a barrier associated with ion hopping, it was discovered that for LiBr it is also affected by the defect formation energy – an energy found to be substantially lower than predicted by DFT. Furthermore, it is shown that when reaction rates for different relative amounts of reactants are varied, it is possible to identify the rate-limiting reagent and to elucidate an overall scaling relationship that controls the concentration-dependence of the reaction rate. Also, it is demonstrated that global fits across doped and undoped salts can be used to probe both intrinsic and extrinsic vacancy concentrations. This improved understanding of ion exchange mechanisms can be used to accelerate ion exchange reaction rates by orders of magnitude. In conclusion, the techniques demonstrated here can be broadly applied to probe the kinetics and thermodynamics of solid state reactions.

36 MATERIALS SCIENCE↗