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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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DOE OSTI2022

Quantifying Energy Flows in PV Circularity Processes: Preprint

As sustainability and end-of-life management become a hot topic to timely address in the PV community, a proper evaluation of the benefits of circular pathways such as recycling, reuse, and remanufacturing has not been performed holistically beyond material flows or LCA analysis. Energy flows are critical for evaluating energy generation technologies. Previously they have been used to compare renewables to fossil generation and then between PV technologies. This paper brings energy flows to bear on reaching circular pathways for PV. The energy flows to track energy usage, generation, and losses complementary to the mass flows are presented for silicon through the leverage of the PV ICE framework.

circular economy↗

DOE OSTI2022

Quantifying Energy Flows in PV Circularity Processes

As sustainable deployment and end-of-life management become a hot topic to timely address in the PV community, a dynamic comparative evaluation of the benefits of circular pathways such as reuse, and remanufacturing, recycling has not been performed holistically beyond material flows or LCA analysis. Energy flows are critical for evaluating energy generation technologies. Previously they have been used to compare renewables to fossil generation and then between PV technologies. This paper quantifies energy flows to evaluate circular pathways for PV. The energy flows tracking manufacturing, generation, and losses complementary to the mass flows of silicon are quantified leveraging the PV ICE framework.

circular economy↗

NASA NTRS1983

The Trend of Future Gas Turbine Technology

Turbomachinery system component research to advance the technology of aviation turbofan and turbojet engines is discussed. Areas of research include compressors, turbines, internal flow analysis, combustion, fuels, materials, structures, bearings, seals, lubrication, dynamics and controls, and instrumentation. A review of the research directions being taken in these areas and the steady advances being made provides a reasonable glimpse at gas turbine technology of the future.

Hartman, M. J.↗

NASA NTRS1984

The trend of future gas turbine technology

Future gas turbine technology will be based on contributions to the technology base being made today. At the NASA Lewis Research Center in Cleveland, OH, research is being conducted on turbomachinery system components and in a number of associated disciplines to advance the technology of aviation turbofan and torbojet engines. Areas of research include compressors, turbines, internal flow analysis, combustion, fuels, materials, structures, bearings, seals, lubrication, dynamics and controls, and instrumentation. A review of the research directions being taken in these areas and the steady advances being made provides a reasonable glimpse at gas turbine technology of the future.

Hartmann, M. J.↗

NASA NTRS1997

Analysis of Flow From Arc-Jet Spectra

Materials testing is carried out at the JSC Atmospheric Reentry Materials and Structures Facility. A flow diagnostics program is under development to characterize the energy distribution in arc-jet flows used to simulate atmospheric entry. Heat transfer to materials depends on flow properties which includes the composition of and energy distribution among the atoms, ions, molecules, and molecular ions which make up the flow. This project involves analysis of shock layer characteristics from the radiation emitted and experimentally collected from near the front of the shock to near the surface of the material. The analysis has yielded information on relative populations of neutral molecules and molecular ions within the layer. In determining non-equilibrium temperatures within the layer, some insight into the spectral constants used to compute radiative emission has been gained.

Blackwell, H. E.↗

DOE OSTI2022

Regional analysis of aluminum and steel flows into the American automotive industry

Aluminum and steel represent the two most dominant metals in light duty vehicles, yet the flows of these materials into the American automotive industry have not been well characterized. This study proposes and implements a method for analyzing the flow of these metals into the automotive industry. We create a framework for performing regionally linked, sector specific material flow analyses and use this framework to trace flows of aluminum and steel entering the American automotive industry, focusing on flows downstream from raw material production. We show that automotive aluminum sheet and extrusions are sourced primarily from the NPCC (23%), SERC (20%), MRO (18%), and RFC (13%) NERC regions and a spatially unresolved Local region within the U.S. and Canada (18%). We determine that primary aluminum is largely from Canada (70%), nearly all from Quebec (69%). Further upstream, alumina and bauxite originate mostly from Brazil, Australia, and Jamaica. We also show that finished automotive steel is sourced primarily from the RFC (63%) and SERC (20%) regions. The crude steel supply similarly originates mainly from the RFC (69%) and SERC (7%) regions. Upstream raw materials including coke, coking coal, iron ore, lime, and steel scrap are primarily sourced from the U.S. with only direct reduced iron and pig iron used in electric arc furnace steel production coming mostly from outside the U.S. The framework developed here allows for increased spatial resolution of material flows, which can be used to develop more specific life cycle impact factors for life cycle assessments.

aluminum↗

DOE OSTI2023

Numerical Analysis of Regular Material Point Method and its Application to Multiphase Flows

The material point method (MPM) is gaining wide popularity in engineering research to model and simulate complex multiphase flow dynamics. The method relies on solving the governing equations of motion and transport in a Lagrangian framework using particles also known as material points. The fluid and kinematic properties are stored on the material points while the spatial gradient calculation and temporal integration are performed on a background grid. This Lagrangian framework allows for large deformations, easy integration of constitutive models, and direct import of complex geometries as particles. However, despite their increasing popularity, very few studies have addressed the issues of numerical resolution and stability of MPM techniques. The presence of additional factors such as the number of material points-per-cell, the location of the material points, the CFL-like condition used in time update, and the grid shape functions also increase the complexity of the error analysis when compared to other finite element methods. In this presentation, we analyze the various forms of error incurred in the application of MPM to continuum mechanics and multiphase flows. The effect of the previously mentioned factors on the error dynamics is studied. The application of these principles to canonical and industrial problems is also presented.

high pressure reverse osmosis↗

DOE OSTI2021

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Abstract Friction stir extrusion (FSE) is a novel solid-phase processing technique that consolidates and extrudes metal powders, flakes, chips, or billets into high-performance parts by plastic deformation, which has the potential to save substantial processing time and energy. Currently, most studies on FSE are experimental and only a few numerical models have been developed to explain and predict the complex physics of the process. In this work, a meshfree simulation framework based on smoothed particle hydrodynamics (SPH) was developed for FSE. Unlike traditional grid-based methods, SPH is a Lagrangian particle-based method that can handle severe material deformations, capture moving interfaces and surfaces, and monitor the field variable histories explicitly without complicated tracking schemes. These aspects of SPH make it attractive for the FSE process, where in situ evolution of field variables is difficult to observe experimentally. To this end, a 3-D, fully thermomechanically coupled SPH model was developed to simulate the FSE of aluminum wires. The developed model was thoroughly validated by comparing the numerically predicted material flow, strain, temperature history, and extrusion force with experimental results for a certain set of process parameters. The validated SPH model can serve as an effective tool to predict and better understand the extreme thermomechanical conditions during the FSE process.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1982

Advanced technologies for turbomachinery systems: An overview

Turbomachinery system components and associated technologies are discussed. Specific technologies reviewed include the compressor, turbine, internal flow analysis methods, combustion, fuels, materials, structures, bearings, seals, and lubrication, dynamics and controls, and instrumentation. Analytical procedures as a path to improved performance are discussed. The strong interaction between the various technologies if turbomachinery performance gains are to be realized is reflected.

Hartmann, M. J.↗

NASA NTRS1990

Geologic setting of diverse volcanic materials in northern Elysium Planitia, Mars

Geologic mapping of high-resolution (30-50 m/pixel) Viking Orbiter images of northern Elysium Planitia has identified seven sites where current problems in martian volcanology, chronology, and stratigraphy can be resolved. These sites, which are discussed in the context of a potential Mars rover/sample return mission, would permit the following investigations: (1) the dating of Lower Amazonian lava flows from Elysium Mons (thereby providing absolute calibration for global crater size/frequency relative chronologies, (2) the petrologic investigation of long run-out lava flows, (3) the geologic interpretation of materials that may either be lava flows or lahar deposits, (4) the analysis of materials believed to be ash deposits produced by explosive eruptions of Hecates Tholus, and (5) the investigation of the stratigraphy of fractured terrain along the boundary between northern Elysium Planitia and southern Utopia Planitia.

Mouginis-Mark, P. J.↗

DOE OSTI2020

The weakly nonlinear response and nonaffine interpretation of the Johnson–Segalman/Gordon–Schowalter model

We derive new analytical solutions for the non-affine Johnson-Segalman/Gordon-Schowalter (JS/GS) constitutive equation with a general relaxation kernel in medium-amplitude oscillatory shear (MAOS) deformation. The results show time-strain separable (TSS) nonlinearity, therefore providing new physically-meaningful interpretation to the heuristic TSS nonlinear parameter in MAOS. The upper-convected, lower-convected, and corotational Maxwell models are all subsets of the results presented here. The model assumes that the microscale elements causing stress in the material slip compared to the continuum deformation. We introduce a visualization of the non-affine deformation field that acts on stress-generating elements to reinforce the hysical interpretation of the JS/GS class of models. Lastly, a case study is presented where previously published results, from fitting TSS models to MAOS data, can be re-interpreted based on the concept of non-affine motion of the JS/GS framework.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Thermal analysis of M551 experiment for materials processing in space

Heat flow in a disc due to moving heat generated by electron beam was studied analytically. Computer programs based on the finite-element method were developed for the analysis of two and three dimensional mathematical models. The limited experimental data were compared with the analytical results, and factors which had influence on heat flow in the disc were studied. The computer programs were modified to consider the effects of metal melting and solidification as well as radiation. Temperature dependency of thermophysical properties was also considered.

Muraki, T.↗

DOE OSTI2026

Are the U.S. Biorefineries Over the Hurdle of 2000 Ton Daily Throughput Yet?

The efficient utilization of lignocellulosic biomass for biofuel and biochemical production is hindered by material handling issues such as clogging and segregation among other challenges. Preprocessing methods such as drying, screening, and milling have improved conversion yield but have not sufficiently enhanced flowability, especially herbaceous biomass. The poor flowability of herbaceous biomass is rooted in some particle attributes that remain less altered by those methods, e.g., irregular particle shape, high roughness, and high compressibility, making it hard to scale up throughput to a key benchmark for a biorefinery – 2000 ton per day. Applying additional preprocessing methods like pelletization and torrefaction to drastically change those particle attributes can improve flow and handling but has not been comprehensively verified through test. The flowability of herbaceous biomass feedstock formats generated by three different preprocessing methods was recently assessed at Idaho National Laboratory’s Biomass Feedstock National User Facility: first, loose particles size reduced from as-received materials; second, pellets produced from an efficient densification process; and third, powders milled from torrefied pellets. Benchmarking tests including static angle of repose, basic flow energy measured in a powder rheometer, and discharge flow in an adjustable hopper, were conducted to evaluate those feedstock formats. Beyond the capacity of existing experimental apparatuses, a digital engineering approach involving flow simulations and AI models were used to identity the material attributes and processing parameters that have dominant influences on flow throughput. Techno-economic analysis focusing on hopper flow as a typical material handling operation was conducted for those feedstock formats. Perspectives will be discussed on whether the 2000-ton daily throughput for a biorefinery is achievable at an acceptable cost by using any of the tested preprocessing methods.

09 - BIOMASS FUELS↗

NASA NTRS1976

Analytical study of the optimum geometric configuration of a space shuttle materials laboratory

A steady state, collisionless flow analysis was made of the density distribution within a hemisphere-disc system due to independent, uniformly distributed internal gas sources. The model was used to estimate the density within a molecular shield, deployed from the shuttle orbiter, which contained internal experiments having a prescribed gas source. Contour plots of the density distribution within the system were presented for disc-to-hemisphere radius ratios of .1, .3, .5, .7, and for disc-to-hemisphere surface emission flux density ratios of .01, 1, 100. The hemisphere-disc system was compared to the empty hemisphere, and it was found that if the disc emission flux density was the same as the hemisphere and the disc radius was not greater than 1/3 of the hemisphere radius, the increase in density at the center of the hemisphere-disc system was less than 50%.

Clay, F. P., Jr.↗

NASA NTRS1971

Design and fabrication of brayton cycle solar heat receiver

A detail design and fabrication of a solar heat receiver using lithium fluoride as the heat storage material was completed. A gas flow analysis was performed to achieve uniform flow distribution within overall pressure drop limitations. Structural analyses and allowable design criteria were developed for anticipated environments such as launch, pressure containment, and thermal cycling. A complete heat receiver assembly was fabricated almost entirely from the refractory alloy, niobium-1% zirconium.

Mendelson, I.↗

NASA NTRS1960

The Effect of a Deceleration Force on a Melting Boundary Layer

Most analytical studies of ablating layers which melt before they vaporize have been restricted to the stagnation region of bodies (e.g., see Sutton). To determine conditions all along the body, it is important to include the deceleration force that opposes the downstream flow of liquid. Some treatment has already been given to this problem, but it is rather limited because of the idealization of the considered configuration or the omission of some important features of the problem. This note gives a more general discussion of the phenomena that occur when a body force acts on a melting boundary layer. The basis for these remarks is an analysis of the flow of a material like Pyrex over a two-dimensional body. The liquid density, specific heat, and conductivity are assumed constant. To determine the conditions under which deceleration effects are important and to simplify the basic equations, all variables except velocity and time are made dimensionless in the usual way.

Ostrach, Simon↗

DOE OSTI2020

Combining Reclaimed PET with Bio-Based Monomers Enables Plastics Upcycling

Less than 30% of PET plastic is recycled in the United States. The low reclamation rate may be due to mechanical recycling accounting for the majority of commercial PET recycling. Mechanical recycling yields a lower-quality recycled plastic than the process of chemically recycling back to the monomer phase, which can be energetically and economically expensive. In this work, recently published in Joule, reclaimed PET bottles are chemically recycled and converted into higher-value fiberglass-reinforced plastics (FRPs).This presentation will focus on the supply-chain level energy and greenhouse gas emissions intensities associated with this novel upcycling route. The Materials Flows through Industry supply chain analysis tool, developed at NREL, is used to estimate these impacts. Depending on the extent and speed of adoption, this strategy for plastic upcycling could lead to significant energy usage and emissions reductions over the traditional FRP supply chain. Overall, this approach may provide an economic incentive for plastics recycling and renewable feedstock use through the creation of higher-value FRPs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Plastic Parallel Pathways Platform- 4P Model

The U.S. generates 42 million metric tons of plastic waste each year - the most of any country - of which less than 9% is recycled. This represents an estimated loss of $2.3 billion and 3.4 EJ embodied energy per year. Plastic use reduction, reuse and recycling are thus increasingly important, but making informed policy and research decisions within this space can be challenging given the diverse range of available solutions. Various recycling and waste management options are available for plastics, such as conversion into energy (incineration, pyrolysis, gasification), conversion to lower- or higher-grade plastics (mechanical recycling, chemical or enzymatic depolymerization processes, dissolution) or up-cycling to feedstock chemicals (photo/electro/catalytic methods, pyrolysis, gasification). While many previous publications have investigated a subset of these options, there is currently no modelling platform that can quantitatively assess and compare the economic and environmental impacts of all these different plastic management pathways and their respective products simultaneously. To directly compare the benefits and disadvantages of plastic-to-x technologies, we propose a novel analysis framework: the Plastic Parallel Pathways Platform (4P). 4P will model a systems analysis framework for capturing plastic material flows processed via different waste management scenarios. The total economic cost and greenhouse gas emissions (as well as additional economic, energetic, and environmental metrics indicators) of a given scenario will be calculated enabling comparison to other scenarios, thereby informing decisions on plastic recycling pathways.

circular economy↗