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Results for “Casting Optimization”

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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Single Crystal Casting with Fluidized Carbon Bed Cooling: A Process Innovation for Quality Improvement and Cost Reduction

Superalloy gas turbine blades are being produced by investment casting and directional solidification. A new process, Fluidized Carbon Bed Cooling (FCBC), has been developed and is now being optimized in a prototype casting unit with 10 kg pouring weight. In early test runs with still rather simple mold cluster geometries, a reduction of the primary dendrite arm spacing of around 40 pct compared to the standard radiation cooling process (HRS) could be demonstrated. The improvement is mainly attributed to higher temperature gradients driving solidification, made possible by a functioning Dynamic Baffle. Compared to earlier development efforts in the literature, contamination of the melt and damage to the equipment are avoided using carbon-based fluidized bed materials and the so-called “counter pressure concept.”.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Optimization of Lithium Content and Sintering Additives in Tape Cast Lithium Garnet Electrolyte Sheets

The lithium garnet (LLZO) remains one of the most promising electrolyte materials for producing solid state batteries. Tape casting is one method for producing the thin ceramic electrolyte layer required for a high-performance solid state battery. Processing of LLZO is complicated by several factors including lithium volatilization, abnormal grain growth and phase instability. Many of these issues are exacerbated in tape cast sheets by the sheets' higher surface area to volume ratio, when compared to pellet processing methods. Here, we report on an environmentally friendly aqueous tape casting process for LLZO using methylcellulose as a binder and compare final sheet properties to other, solvent-based, options. Solids loading, binder content, dispersant composition, and wetting agent type are varied to improve ease of casting and enhance properties of the as-cast tape. Lithium content in sintered LLZO sheets is controlled by the inclusion of excess Li 2 CO 3 as lithium source in the ceramic tape itself and by a novel method of producing a lithium-saturated furnace atmosphere. Sintering time and temperature are optimized, and rapid thermal processing is investigated as a method of reducing lithium loss. Al 2 O 3 and MgO are examined for use as sintering additives. Characterization of LLZO sheets is performed with XRD, EIS and SEM. Li 2 CO 3 and sintering additive levels are optimized for ionic conductivity and density. The optimization effort improved the conductivity and density of 100µm thick sintered sheets to greater than 3x10 -4 S/cm conductivity and 90% density.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Modeling of interdendritic porosity defects in an integrated computational materials engineering approach for metal casting

Modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components in order to accelerate the introduction of new cast alloys. The data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. Here in this paper, the required models for the prediction of interdendritic casting defects, such as microporosity and hot tears, are reviewed. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Numerical simulation results for microporosity are presented for A356, 356 and 319 aluminum alloys using ProCAST TM software. The calculated pressure drop of the interdendritic liquid was observed to be quite significant and the regions of high-pressure drop can be used as an indicator of the severity of interdendritic microporosity defects.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Selective Heating Through Y-Junction Waveguide Designed by Acoustic Shape Optimization

Unlike phononic crystals or systems designed by topology optimization, waveguides designed by shape optimization do not have voids or internal defects, making the fabrication process more suitable for additive manufacturing. By designing a Y-junction waveguide through shape optimization, an ultrasonic wave can be controlled so that it propagates to a predetermined location just by adjusting its frequency. These demultiplexed ultrasonic waves can be used to transport signals or stimulate nearby materials. As an example, the ultrasonic wave is converted to heat at different locations, which can be applied to mechanisms that can take advantage of heating. First, shape optimization is performed on a cylindrical structure to selectively propagate ultrasonic waves of a particular frequency while attenuating others, which is analyzed through a finite element model. The numerical study results are compared with experimental measurements from samples fabricated through additive manufacturing methods. After verifying the concept, the Y-junction waveguide is fabricated to demultiplex the wave and selectively heat different locations. Here the results show that the method of combining shape optimization with additive manufacturing is exceptionally simple and capable of demultiplexing ultrasonic waves, which can replace complex electrical components with single-material waveguides.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Multi-Stage Stochastic Programming to Joint Economic Dispatch for Energy and Reserve With Uncertain Renewable Energy

To address the uncertain renewable energy in the day-ahead optimal dispatch of energy and reserve, a multi-stage stochastic programming model is established in this paper to minimize the expected total costs. The uncertainties over the multiple stages are characterized by a scenario tree and the optimal dispatch scheme is cast as a decision tree which guarantees the flexibility to decide the reasonable outputs of generation and the adequate reserves accounting for different realizations of renewable energy. Most importantly, to deal with the “Curse of Dimensionality” of stochastic programming, stochastic dual dynamic programming (SDDP) is employed, which decomposes the original problem into several sub-problems according to the stages. Specifically, the SDDP algorithm performs forward pass and backward pass repeatedly until the convergence criterion is satisfied. At each iteration, the original problem is approximated by creating a linear piecewise function. Besides, an improved convergence criterion is adopted to narrow the optimization gaps. The results on the IEEE 118-bus system and real-life provincial power grid show the effectiveness of the proposed model and method.

economic dispatch↗
NASA NTRS2007

Freeze Tape Casting of Functionally Graded Porous Ceramics

Freeze tape casting is a means of making preforms of ceramic sheets that, upon subsequent completion of fabrication processing, can have anisotropic and/or functionally graded properties that notably include aligned and graded porosity. Freeze tape casting was developed to enable optimization of the microstructures of porous ceramic components for use as solid oxide electrodes in fuel cells: Through alignment and grading of pores, one can tailor surface areas and diffusion channels for flows of gas and liquid species involved in fuel-cell reactions. Freeze tape casting offers similar benefits for fabrication of optimally porous ceramics for use as catalysts, gas sensors, and filters.

Sofie, Stephen W.↗
DOE OSTI2018

Influence of Sc content on the microstructure and mechanical properties of cast Al-2Li-2Cu-0.5Mg-0.2Zr alloy

Highlights: • The grain size was continuously reduced with the increasing Sc content. • No evidence for the formation of the Cu-rich and Sc-containing W phase was observed. • Sc addition could promote the precipitation of S′ in the absence of pre-age stretch. • Sc addition would reduce the growth rate of δ′ and δ′-PFZs. • The highest combinations of strength and ductility were obtained in cast Al-Li alloys. - Abstract: In this work, the influence of Sc content on the microstructure and mechanical properties of cast Al-2Li-2Cu-0.5Mg-0.2Zr alloy was investigated. It was found that the grain size of As-cast alloy was significantly reduced in steps with the increase of Sc addition, accompanied by the arising and increasing of cubic primary Al{sub 3}(Sc, Zr) phases. No evidence for the presence of the ternary W (Al{sub 8−x}Cu{sub 4+x}Sc) phase was obtained. The volume fraction of nanoscale Al{sub 3}(Sc, Zr) dispersoids was improved with the increase of Sc content, and the presence of Sc was observed to refine the S′ (Al{sub 2}CuMg) morphology during ageing. The addition of Sc lowered the growth rates of δ′ (Al{sub 3}Li) particles and δ′-Precipitate-free zones (δ′-PFZs) of the base alloy. The tensile property results showed that, with the increasing Sc content and ageing times, the yield strength (YS) and ultimate tensile strength (UTS) were continuously increased, and the highest elongation of 6.0% was obtained in the 0.2Sc-containing alloy aged for 32 h at 175 °C. The results indicated that the optimal Sc addition in cast Al-2Li-2Cu-0.5Mg-0.2Zr alloy was 0.2 wt%.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Key parameters controlling the performance of catalytic motors

The development of autonomous micro/nanomotors driven by self-generated chemical gradients is a topic of high interest given their potential impact in medicine and environmental remediation. Although impressive functionalities of these devices have been demonstrated, a detailed understanding of the propulsion mechanism is still lacking. In this work, we perform a comprehensive numerical analysis of the key parameters governing the actuation of bimetallic catalytic micropumps. We show that the fluid motion is driven by self-generated electro-osmosis where the electric field originates by a proton current rather than by a lateral charge asymmetry inside the double layer. Hence, the surface potential and the electric field are the key parameters for setting the pumping strength and directionality. The proton flux that generates the electric field stems from the proton gradient induced by the electrochemical reactions taken place at the pump. Surprisingly the electric field and consequently the fluid flow are mainly controlled by the ionic strength and not by the conductivity of the solution, as one could have expected. We have also analyzed the influence of the chemical fuel concentration, electrochemical reaction rates, and size of the metallic structures for an optimized pump performance. Our findings cast light on the complex chemomechanical actuation of catalytic motors and provide important clues for the search, design, and optimization of novel catalytic actuators.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Enable superior performance of ultra-high loading electrodes through the cost-efficient solvent-free electrode manufacturing technology

This research explores an innovative solvent-free method for fabricating ultra-high loading NMC811 and graphite electrodes (~6mAh∙cm -2 ), showcasing remarkable electrochemical performance enhancements compared to the electrodes prepared by the conventional slurry-casting method. Here, the optimized microstructure with dry-printed (DP) electrodes enhanced electrolyte penetration and minimized lithium-ion diffusion tortuosity resulting in improved rate performance at high current rates. Additionally, this innovative electrode manufacturing approach enables more uniform CEI and SEI formation and growth, which effectively doubles the cycle life of single-layer pouch cells with DP electrodes. Beyond the performance enhancements, this method also offers a notable 29.2 % overall cost advantages, potentially revolutionizing future battery manufacturing. The findings presented in this work underscore the potential of solvent-free manufacturing technology as a high-loading capable and cost-efficient path for advanced battery production.

25 ENERGY STORAGE↗
DOE OSTI2020

Bus Clustering for Distribution Grid Topology Identification

Recovering the distribution grid topology is essential to perform several distribution system operator functions. Many algorithms that address the topology recovery problem have already been proposed in the literature. Most are based on a priori information regarding which buses are fed by which substation; however, this information might not be available because frequent grid reconfigurations change the distribution grid portion connected to each substation. This paper addresses the problem of assigning every substation the set of buses that it is feeding, given field data. First, the aforementioned task is cast as a nonconvex optimization problem. Second, a relaxed version of the optimization problem is solved via the alternating direction method of multipliers. Finally, the performance of our approach is validated through numerical simulations of realistic scenarios using a standard IEEE benchmark feeder.

bus clustering↗
DOE OSTI2018

Gelcasting low-carbon B4C for cermets (Allison intern SULI paper)

A boron carbide (B 4 C) gelcasting suspension involving melamine formaldehyde (MF) resin was developed to obtain green bodies with low carbon after pyrolysis. MF resin allows highly complicated B 4 C parts to be produced with little to no shrinkage when gelcast into molds. A MF binder content of ~7.5 wt % consistently produced green bodies with sufficient strength to withstand demolding and handling. Variations in B 4 C particle size, curing temperature, and pH were investigated in order to optimize the suspension for casting. Resin pyrolysis trials showed that 90.0 ± 0.9 wt % of resin mass was lost during pyrolysis, corresponding to < 1 wt % of binder residual in the overall green bodies. The minimal carbon content in the green bodies is favorable for the infiltration of aluminum into open pore spaces. Due to the high hardness of B 4 C and the ductility of aluminum, the ceramic-metal (cermet) composite formed is ideal for applications such as light-weight armors.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Robust Resilient Signal Reconstruction under Adversarial Attacks

We consider the problem of signal reconstruction for a system under sparse signal corruption by a malicious agent. The reconstruction problem follows the standard error coding problem that has been studied extensively in the literature. We include a new challenge of robust estimation of the attack support. The problem is then cast as a constrained optimization problem merging promising techniques in the area of deep learning and estimation theory. A pruning algorithm is developed to reduce the "false positive" uncertainty of data-driven attack localization results, thereby improving the probability of correct signal reconstruction. Sufficient conditions for the correct reconstruction and the associated reconstruction error bounds are obtained for both exact and inexact attack support estimation. Moreover, a simulation of a water distribution system is presented to validate the proposed techniques.

Robust, Signal reconstruction, Resilient estimator↗
NASA NTRS1994

Improving Learning Performance Through Rational Resource Allocation

This article shows how rational analysis can be used to minimize learning cost for a general class of statistical learning problems. We discuss the factors that influence learning cost and show that the problem of efficient learning can be cast as a resource optimization problem. Solutions found in this way can be significantly more efficient than the best solutions that do not account for these factors. We introduce a heuristic learning algorithm that approximately solves this optimization problem and document its performance improvements on synthetic and real-world problems.

resource optimization↗
NASA NTRS2005

Small Body GN&C Research Report: A Guidance and Control Technique for Small-Body Proximity Operations with Guaranteed Guidance Resolvability and Required Thruster Silent Time

The guidance and control (G&C) algorithms for enabling small-body proximity operations are developed by using a model predictive control approach along with a convexification of the governing dynamics, control constraints, and trajectory/state constraints. The open-loop guidance is solved ahead of time or in a resolvable, real-time manner through the use of PWG (Pseudo Way-point Generation), a technique developed in this research. The PWG scheme ensures required thruster silent times during trajectory maneuvers. The feedback control is implemented to track the PWG trajectories in a manner that guarantees the resolvability for the open-loop problem, enabling the ability to update the G&C in a model-predictive manner. The schemes incorporate gravity models and thruster ring times into discrete dynamics that are solved as a optimal control problem to minimize fuel consumption or thruster energy expenditure. The optimal control problem is cast as an LMI (Linear Matrix Inequality) and then solved through Semi-Definite Programming techniques in a computationally efficient manner that provides convergence and constraint guarantees.

guidance and control (G&C)↗
DOE OSTI2022

Degeneracy engineering for classical and quantum annealing: A case study of sparse linear regression in collider physics

Classical and quantum annealing are computing paradigms that have been proposed to solve a wide range of optimization problems. In this paper, we aim to enhance the performance of annealing algorithms by introducing the technique of degeneracy engineering, through which the relative degeneracy of the ground state is increased by modifying a subset of terms in the objective Hamiltonian. We illustrate this novel approach by applying it to the example of ℓ 0 -norm regularization for sparse linear regression, which is, in general, an NP-hard optimization problem. Specifically, we show how to cast ℓ 0 -norm regularization as a quadratic unconstrained binary optimization (QUBO) problem, suitable for implementation on annealing platforms. As a case study, we apply this QUBO formulation to energy flow polynomials in high-energy collider physics, finding that degeneracy engineering substantially improves the annealing performance. Furthermore, our results motivate the application of degeneracy engineering to a variety of regularized optimization problems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Development of Repair Techniques for Cast Iron Engine Blocks by Additive Manufacturing

ORNL partnered with Cummins Inc to demonstrate the feasibility of using additive manufacturing techniques to deposit large volume of new material on cast iron in the context of remanufacturing. Remanufacturing at Cummins Inc is carried out to repair any field damage and, in some cases, provide additional value by adding new features. Large volume deposition on difficult to weld materials is a challenging problem due to involved metallurgy. Phase-1 of this work evaluated the feasibility of using laser directed energy deposition technique to deposit new material layer by layer on cast iron engine blocks. During phase-1 deposits were made using Inconel-718, Nickel, Nr-Cr-B braze filler. Leveraging the knowledge gained during Phase-1, Phase-2 focused on developing a low- cost crack resistant ferrous alloy to repair cast iron via volume deposition techniques without preheating. Three different alloy chemistries were identified, and trials were performed on cast iron substrates to identify the optimal chemistry that provided adequate resistance to cracking in both, the deposits as well as the cast iron substrate.

42 ENGINEERING↗
DOE OSTI2018

Optimization of Hot Deformation Parameters and Constitutive Analysis for As-Cast Mg-5Li-3Zn-0.3Y Alloy Using Processing Maps

Hot deformation behavior of as-cast Mg-5Li-3Zn-0.3Y (wt.%) alloy has been studied by establishing processing maps covering the range of 200-450 °C in temperature and 0.001-10 s{sup −1} in strain rate. The map corresponding to the strain of 0.7 reveals that a domain of dynamic recrystallization occurred at 340-400 °C/0.01-0.158 s{sup −1} with its peak efficiency of approximately 31%. Analysis of the flow behaviors and microstructural observations indicated that dynamic recrystallization occurred in the domain, in which fine microstructure can be achieved. The above conditions represent the optimum processing parameters, and the flow instability regimes are also recognized from the maps. The average deformation in the deformed range was 136.414 kJ/mol which is close to that for lattice self-diffusion in magnesium and far smaller than that for as-cast Mg-5.75Zn-0.73Y-0.36Zr (wt.%) alloy. It is believed that a lower activation energy for Mg-5Li-3Zn-0.3Y alloy can partly result from both the weak particle pinning effects and adding Li into the Mg-Zn-Y-Zr alloy. Results of extrusion experiments conducted at 350 °C show that the alloy can be easily extruded with good mechanical properties of the yield strength of 132 MPa, the fracture strength of 215 MPa and the elongation of 20.9%, and the grains can be well refined.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Method and apparatus for in-situ drying investigation and optimization of slurry drying methodology

A method of drying casted slurries that includes calculating drying conditions from an experimental model for a cast slurry and forming a cast film. An infrared heating probe is positioned on one side of the casted slurry and a thermal probe is positioned on an opposing side of the casted slurry. The infrared heating probe may control the temperature of the casted slurry during drying. The casted slurry may be observed with an optical microscope, while applying the drying conditions from the experimental model. Observing the casted slurry includes detecting the incidence of micro-structural changes in the casted slurry during drying to determine if the drying conditions from the experimental model are optimal.

36 MATERIALS SCIENCE↗