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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Configuration Management of an Optimization Application in a Research Environment

Multidisciplinary design optimization (MDO) research aims to increase interdisciplinary communication and reduce design cycle time by combining system analyses (simulations) with design space search and decision making. The High Performance Computing and Communication Program's current High Speed Civil Transport application, HSCT4.0, at NASA Langley Research Center involves a highly complex analysis process with high-fidelity analyses that are more realistic than previous efforts at the Center. The multidisciplinary processes have been integrated to form a distributed application by using the Java language and Common Object Request Broker Architecture (CORBA) software techniques. HSCT4.0 is a research project in which both the application problem and the implementation strategy have evolved as the MDO and integration issues became better understood. Whereas earlier versions of the application and integrated system were developed with a simple, manual software configuration management (SCM) process, it was evident that this larger project required a more formal SCM procedure. This report briefly describes the HSCT4.0 analysis and its CORBA implementation and then discusses some SCM concepts and their application to this project. In anticipation that SCM will prove beneficial for other large research projects, the report concludes with some lessons learned in overcoming SCM implementation problems for HSCT4.0.

Townsend, James C.↗
NASA NTRS2000

Influence of the Biosphere on Precipitation: July 1995 Studies with the ARM-CART Data

Ensemble sets of simulation experiments were conducted with a single column model (SCM) using the Goddard GEOS II GCM physics containing a recent version of the Cumulus Scheme (McRAS) and a biosphere based land-fluxes scheme (SSiB). The study used the 18 July to 5 August 1995 ARM-CART (Atmospheric Radiation Measurement-Cloud Atmospheric Radiation Test-bed) data, which was collected at the ARM-CART site in the mid-western United States and analyzed for single column modeling (SCM) studies. The new findings affirm the earlier findings that the vegetation, which increases the solar energy absorption at the surface together with soil and soil-moisture dependent processes, which modulate the surface, fluxes (particularly evapotranspiration) together help to increase the local rainfall. In addition, the results also show that for the particular study period roughly 50% of the increased evaporation over the ARM-CART site would be converted into rainfall with the Column, while the remainder would be advected out to the large-scale. Notwithstanding the limitations of only one-way interaction (i.e., the large-scale influencing the regional physics and not vice versa), the current SCM simulations show a very robust relationship. The evaporation-precipitation relationship turns out to be independent of the soil types, and soil moisture; however, it is weakly dependent on the vegetation cover because of its surface-albedo effect. Clearly, these inferences are prone to weaknesses of the SCM physics, the assumptions of the large-scale being unaffected by gridscale (SCM-scale) changes in moist processes, and other limitations of the evaluation procedures.

Sud, Y. C.↗
NASA NTRS2004

A Novel Spacecraft Charge Monitor for LEO

Five years ago we introduced a new method for measuring spacecraft chassis floating potential relative to the space plasma (absolute spacecraft potential) in low Earth orbit. The method, based on a straightforward interpretation of photoelectron spectra, shows promise for numerous applications, but has not yet been tried. In the interest of testing the method, and ultimately supplying another tool for measuring absolute spacecraft charge, we are producing a flight prototype Spacecraft Charge Monitor (SCM) with support from NASA's Small Business Innovation Research (SBIR) program. Although insight into the technique came from data collected in space over two decades ago, very little data are available. The data indicate that it may be possible to determine spacecraft floating potential to within 0.1 volt each with the SCM second under certain conditions. It is debatable that spacecraft floating potential has ever been measured with such accuracy. The compact, easily deployed SCM also offers the advantage of long-term stability in calibration. Accurate floating potential determinations from the SCM could be used to correct biases in space plasma measurements and evaluate charge mitigation and/or sensing devices. Although this paper focuses on the device's use in low Earth orbit (LEO), the device may also be able to measure spacecraft charge at higher altitudes, in the solar wind, and in orbits around other planets. The flight prototype SCM we are producing for delivery to NASA in the third quarter of 2004 will measure floating potential from 0 to -150 volts with 0.1 volt precision, weigh approximately 600-700 grams, consume approximately 2 watts, and will measure approximately 8 x 10 x 17 cm.

Goembel, Luke↗
NASA NTRS2004

SCDM in a Distributed Environment

The Software Configuration Management (SCM) of the Space Launch Initiative (SLI) Advanced Engineering Environment (AEE) products is performed in a distributed environment-meaning the activities performed during the project lifecycle are across numerous NASA Centers, facilities, organizations, colleges and industry. SCM is the glue that holds the project and products together-especially in a distributed environment. It identifies, controls, accounts, and verified the details of the products; the schedule of activities; the assigned responsibilities; and the required resources, including staff, tools, and computer facilities. Data/document management (DM) captures and conveys the SCM and project efforts. SCM and DM are integrally linked; hence, Software Configuration and Data Management (SCDM). This paper discusses one team's challenges in implementing SCDM in a distributed environment. The distributed nature of the project introduces new opportunities for moving SCDM to the next level of usefulness in today's high-tech development arena. The lessons learned from the implementation of distributed SCDM in support of the SLI AEE Project provide valuable information for future implementations of SCM and DM.

Crowley, Sandra L.↗
NASA NTRS2013

A Single-column Model Ensemble Approach Applied to the TWP-ICE Experiment

Single-column models (SCM) are useful test beds for investigating the parameterization schemes of numerical weather prediction and climate models. The usefulness of SCM simulations are limited, however, by the accuracy of the best estimate large-scale observations prescribed. Errors estimating the observations will result in uncertainty in modeled simulations. One method to address the modeled uncertainty is to simulate an ensemble where the ensemble members span observational uncertainty. This study first derives an ensemble of large-scale data for the Tropical Warm Pool International Cloud Experiment (TWP-ICE) based on an estimate of a possible source of error in the best estimate product. These data are then used to carry out simulations with 11 SCM and two cloud-resolving models (CRM). Best estimate simulations are also performed. All models show that moisture-related variables are close to observations and there are limited differences between the best estimate and ensemble mean values. The models, however, show different sensitivities to changes in the forcing particularly when weakly forced. The ensemble simulations highlight important differences in the surface evaporation term of the moisture budget between the SCM and CRM. Differences are also apparent between the models in the ensemble mean vertical structure of cloud variables, while for each model, cloud properties are relatively insensitive to forcing. The ensemble is further used to investigate cloud variables and precipitation and identifies differences between CRM and SCM particularly for relationships involving ice. This study highlights the additional analysis that can be performed using ensemble simulations and hence enables a more complete model investigation compared to using the more traditional single best estimate simulation only.

numerical weather forecasting↗
DOE OSTI2022

Single Carrier Modulation Resource Allocation for Massive MIMO with Virtual Antennas

Today’s Massive MIMO cellular operation is dominated by orthogonal frequency division multiplexing (OFDM) modulation. One of the advantages of OFDM is the flexibility to carve up the available spectrum into resource blocks (RBs) that can operate adjacent to one another. Massive MIMO adds spatial multiplexing layers on top of the RBs, enabling the simultaneous operation of dozens of UEs. Cyclic prefixed single carrier modulation (CP-SCM) is an alternative to OFDM that also benefits from massive MIMO and is useful as an OFDM alternative in specific scenarios. However, until recently, no resource allocation method has been proposed for CP-SCM. In this paper, we present a CP-SCM resource allocation scheme using virtual antennas in a massive MIMO time domain duplexed scenario. By creating several virtual antennas for each physical antenna, the benefits of massive MIMO are achieved with a smaller physical antenna count. Resources are quantized into data streams, and each user can be assigned a variable number of simultaneous streams. This paper presents a detailed development and analysis of multi-stream processing (MSP) for both uplink detection and downlink precoding. We also introduce heterogeneous MSP, where CP-SCM and OFDM signals can be processed in the same MSP framework.

5G and beyond communications↗
DOE OSTI2020

Imaging hole-density inhomogeneity in arsenic-doped CdTe thin films by scanning capacitance microscopy

We report nanometer-scale hole-density imaging in As-doped CdTe films by scanning capacitance microscopy (SCM). The hole-density profiling is validated by contrasting a CdTe cross-section sample made by molecular-beam epitaxy with systematically increased As doping in a staircase pattern over the range of 10 15 -10 18 /cm 3 within a single film. In polycrystalline films, the carrier distribution is significantly nonuniform, with inhomogeneity ranging from several hundred nm to several um and hole density varying by one order of magnitude (low 10^16 to low 10 17 /cm 3 ). This nonuniformity is distributed randomly, independent of the grain structure and grain boundaries (GBs). Kelvin probe force microscopy (KPFM) maps the surface potential and is correlated to cathodoluminescence (CL) and SCM by imaging over identical areas. Higher potential and lower CL intensity are found on GBs but not by SCM contrast; this indicates positive GB charging and recombination, but not GB-specific hole-density changes. The overall KPFM potential image is in rough agreement with the SCM carrier distribution and indicates band-edge potential fluctuations. Nonuniform carrier concentration, potential fluctuations, and defect recombination can all cause voltage and performance loss in As-doped CdTe solar technology.

14 SOLAR ENERGY↗
DOE OSTI2025

Insights into the year-round vertical distribution of chlorophyll concentration in high-latitude Arctic Ocean: implications for primary production

Climate-induced rapid changes in the Arctic Ocean, such as decreasing sea ice extent and increasing water temperature, are altering nutrient and light availability, profoundly impacting primary producer growth. However, access to the high-latitude Arctic Ocean is limited, and satellite data are primarily available only during summer, making continuous in-situ data collection challenging. We collected year-round chlorophyll-a (Chl-a) concentration data in high-latitude regions using a mooring system and performed a comparative analysis with reanalysis data. Unlike previous satellite-based studies, which typically rely on surface measurements, we used the annual vertical distribution of Chl-a. These data were applied to the vertically generalized production model to accurately estimate annual primary production. The moored Chl-a concentration data showed that phytoplankton exhibited a typical subsurface chlorophyll maximum (SCM) layer as sea ice retreated in June. Contrary to the gradually deepening SCM distribution predicted by model-based reanalysis data, the SCM layer persisted for approximately 4 months. This indicates that light and nutrient conditions within the SCM layer remained stable, sustaining continuous phytoplankton growth. Annual primary production, reflecting this vertical distribution of Chl-a concentration, was 6.85 gC m −2 yr −1 . This exceeded satellite-based estimates by at least two-fold, highlighting the significant underestimation of primary production by satellite approaches. Estimating primary production while accounting for the vertical distribution of phytoplankton and light is essential for improving ecological models to better understand carbon cycle and food web changes in the Arctic Ocean, with important implications for climate change predictions.

Arctic Ocean↗
DOE OSTI2022

Supercritical Methanol Solvolysis and Catalysis for the Conversion of Delignified Woody Biomass into Light Alcohol Gasoline Bioblendstock

Supercritical methanol (SCM) solvolysis and catalysis has recently emerged as a promising pathway to produce gasoline-range light alcohols from woody biomass through staged depolymerization and hydro-deoxygenation (DHDO). Here, structure-property relationships of Cu"M"AlO x catalysts (M = Mg, Zr, and Ce) are examined for upgrading delignified hybrid poplar via SCM-DHDO. CuCeAlO x displays the highest activity, increasing the C 2 -C 7 alcohol production rate and selectivity by twofold in batch reactions, and >50% in semicontinuous reactions relative to the current state-of-the-art CuMgAlO x . The performance of CuCeAlOx is correlated with its high reducibility and acidity. Cu sintering and biogenic impurity poisoning are identified as possible deactivation mechanisms over 60 h of continuous testing. The gasoline-range SCM-DHDO products are comprised of primarily aliphatic alcohols that result in improved energy density and favorably reduced vapor pressure, relative to ethanol, with the tradeoff of nonsynergistic octane blending with conventional gasoline and lower oxidation stability. Overall, this work highlights the potential to produce suitable light oxygenates by SCM-DHDO processing for gasoline bioblendstock applications.

09 BIOMASS FUELS↗
DOE OSTI2023

Mechanisms of Zn removal from water by amorphous geopolymer: Molecular-level insights from X-ray absorption spectroscopy, isotope fractionation, and surface complexation modeling

Porous geopolymers have attracted widespread attention as promising heavy metal adsorbents that can be synthesized from aluminosilicate solid wastes. However, the precise microstructural evidence for adsorbed heavy metals on geopolymers remains unclear due to the insensitivity of conventional characterization techniques on minerals with amorphous structure and surface disorder. Batch adsorption and column experiments coupled with X-ray absorption spectroscopy (XAS), Zn stable isotope, and surface complexation model (SCM) were employed to reveal the Zn removal mechanisms with coal fly ash porous geopolymer (CFAPG) at a molecular scale. The macroscopic kinetic and isothermal adsorption of Zn on CFAPG were well described by the pseudo-second-order model and Bi_Langmuir equation, respectively, indicating the presence of abundant heterogeneous active sites on the CFAPG surface. Further, two types of active sites on the CFAPG surface were identified by XAS coupled with Zn isotopes in batch experiments at pH <= 6.0: one is pH-dependent and associated with tetrahedral zinc coordi-nation, and the other is pH-insensitive and associated with octahedral zinc coordination; these sites were confirmed by the bidentate SCM as the variable charge site (surface complexation, >S-OH) and the permanent negative charge site (cation exchange, >X - ), respectively. Furthermore, the important contribution of surface co -precipitation besides surface complexation and cation exchange to the Zn adsorption on CFAPG was identified by XAS coupled with SCM in a flow-through column experiment at pH >6.0. These investigations provide a systemic understanding of the Zn adsorption mechanisms on CFAPG and an SCM reference for the application and prediction of geopolymers in heavy metal-contaminated water remediations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Towards ternary binders involving limestone additions — A review

The review summarises literature to examine the transition from portland limestone cement system to composite ternary binder systems involving limestone. Interest in limestone addition as an ideal component in multicomponent binder systems has surged as evident from the large volume of literature published in the recent past. A ternary blended system, with co-substitution of limestone, has the potential to complement the reaction of the supplementary cementitious materials (SCMs). The direct addition of limestone powder helps to attain higher substitution levels of portland cement clinker, improve early age properties, and supplement SCM's reactivity. However, the dilution of hydrates could hamper the long-term benefits. In this review, the interaction of fine limestone is classified and elaborated under two broad umbrellas: physical and chemical interactions. The physical interactions can manifest in three ways, namely, filler action, shearing action and improved packing, which alters reaction rate and extent at early ages. The chemical interactions also modify the reaction kinetics and phase assemblage due to nucleation of C-S-H on calcite surfaces, preservation of the ettringite phase and formation of carboaluminates. Two different forms of carboaluminate hydrates — hemicarboaluminate and mono-carboaluminate can be present in the hydrate matrix depending on the balance between carbonate ions and aluminates in the pore solution. Several factors such as replacement level, particle size, choice of SCM, its reactivity and reactive aluminates content, sulphate levels, curing temperature, and duration of curing can control the carboaluminate formation, reaction degree of SCMs and chemical interaction from limestone additions. A combination of physical and chemical effects makes fine limestone a potential material for co-substitution with aluminosilicate based SCMs, mainly fly ash, slag, and calcined clay. In this review, the factors affecting limestone-SCM composites are summarised based on a detailed literature survey. The effects of SCM-limestone cement composites on hydration kinetics, reaction chemistry, the reactivity of SCMs, the stability of hydrated phases, and contribution to the physical structure development and macroscopic properties by evaluating hydration and mechanical properties are discussed. The importance of AFm (Al{sub 2}O{sub 3}–Fe{sub 2}O{sub 3}-mono) phases in various deterioration mechanisms in concrete and their influence on performance characteristics in different exposure environment is critically appraised.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Selective sulfur removal from semi-dry flue gas desulfurization coal fly ash for concrete and carbon dioxide capture applications

High-sulfur mixed fly ash residues from semi-dry flue gas desulfurization units in coal-fired power plants are unsuitable for use as supplementary cementitious material (SCM) for concrete production or carbon dioxide utilization. In this work, we explore the potential for upcycling a representative spray dry absorber ash (10.44 wt% SO 3 ) into concrete-SCM by selective sulfur removal via weak acid dissolution while simultaneously exploring the possibility for CO 2 capture. Towards this effort, parametric studies varying liquid-to-solid ratio, acidity, and CO 2 pressure were conducted in a batch reactor to establish the sulfur removal characteristics in de-ionized water, nitric acid, and carbonic acid, respectively. The dissolution studies show that the leaching of sulfur from calcium sulfite hemihydrate, which is the predominant S phase, is rapid and achieves a concentration plateau within 5 min, and subsequently, appears to be controlled by the primary mineral solubility. Here, preferential S removal was sufficient to meet SCM standards (e.g., 5.0 wt% as per ASTM C618) using all three washing solutions with 0.62–0.72 selectivity (S^), defined as the molar ratio of S to Ca in the leachate, for a raw fly ash with bulk S^ = 0.3. Acid dissolution with 1.43 meq/g of ash or under 5 atm CO 2 retained > 18 wt% CaO and other Si-, Al-rich phases in the fly ash. Based on the experimental findings, two sulfur removal schemes were suggested for either integration with CO 2 capture and utilization processes using flue gas or to produce fly ash for use as a SCM.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Feasibility of Algal Biochar, a Byproduct of Biofuel Production, as a Supplemental Cementitious Material

Algal biochar, as the solid residue of biofuel production from algal biomass, is reported to explore disposition options, aiming to lessen the liability or obstacles to biofuel production processes. However, landfills and open combustion lead to adverse environmental impacts. One way to add value to such wastes is to use them as admixtures in cementitious construction materials. This study aims to investigate the feasibility of algae-derived biochar as supplementary cementitious materials (SCM) at different water contents and mixture ratios. Algal biochar-cement composites were prepared with different algal biochar content as well as different water-to-cement (w/c) ratios, and the surface area, morphology, elemental, and mineralogical composition were characterized. To compensate for the high-water absorption of algal biochar, a small concentration of a superplasticizer was used since higher w/c ratios negatively impact strength. The mechanical performance of algal biochar-cement composites is compared with control composites using commercial silica fume as a typical commercial SCM. The findings suggest that algal biochar is a promising candidate to replace commercial SCM, like silica fume, since algal biochar-cement composites can reach comparable compressive strength and Young’s modulus to commercial pozzolan-cement materials with the same w/c ratio, though at later curing times, 33 days. Although the tensile strength of algal biochar-cement composites is statistically similar at 7 days, it is significantly lower at later curing times, and further investigation is required to improve this property. Algal biochar-based cement binders showed comparable embodied carbon to silica fume-based cement binders based on a cradle-to-gate lifecycle analysis. However, the ability of algal biochar to absorb large volumes of CO 2 over short periods of time, as measured in this study, makes this novel SCM an excellent alternative to reduce the embodied carbon of concrete structures cradle-to-grave at 1/10 of the cost. In conclusion, valorization of algae-derived solid waste provides great potential to reduce embodied carbon and brings credit to biofuel production and concrete-based construction.

algae-derived↗
DOE OSTI2024

Survey and Gap Prioritization of U.S. Electric Vehicle Charge Management Deployments

The goal of this study was to survey and characterize the scope of current technical and programmatic knowledge pertaining to EV charge management technologies and practices in the US and relevant international jurisdictions. This characterization of existing field demonstrations and knowledge derived were used to determine gaps in the SCM demonstration landscape. Addressing these gaps through research and demonstration could increase confidence in the U.S. that load management and EV charge control could achieve overarching societal benefits. A survey of charge management deployments and input from stakeholders was completed to determine the state-of-the-art of smart charge management (SCM) where SCM is defined as controlling the amount of power exchanged between chargers and EVs to meet customers' charging needs while also responding to external power demand or pricing signals to provide load management, resilience, or other benefits to the customer and electric grid. The survey was the basis of the gap analysis in this report and determines which areas are well understood, with high confidence, and which areas need further investigation. Existing examples of EV charge management are characterized here to determine aspects that are ready for widespread deployment and have been demonstrated in the field. These include demonstration studies, pilots, programs, and EV-specific tariffs. In all, 110 examples of charge management were characterized. The data sources were public literature and utility filings as well as targeted interviews. In addition, 43 interviews with stakeholders were conducted with a consistent set of questions used in each interview. This study prioritized gaps in demonstrated SCM capabilities based on 1) Urgency of the particular use-case to offset traditional grid assets, 2) Impact, extensibility, and scaling of results across the entire spectrum of 3000+ utility service territories including projected technical and market potential for a given grid service, and 3) Value of federal funding in addressing the gap, including potential to leverage and/or add scope to existing field demonstrations funded by other non-federal funding mechanisms.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Leveraging MARVEL and SPHERE to Demonstrate NEAMS Thermal Hydraulics Codes

The Single Primary Heat Extraction and Removal Emulator (SPHERE) and Microreactor Applications Research Validation and Evaluation (MARVEL) were utilized to demonstrate thermal hydraulics codes of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. A recent long-duration test of a sodium heat pipe conducted at the SPHERE facility was utilized for the validation of the heat pipe code Sockeye. The first 10 hours of operation featured a startup of the heat pipe from room temperature; this portion was modeled with Sockeye and compared to the experimental data. Measurements included several thermocouple measurements across the length of the heat pipe surface. Two of Sockeye’s heat pipe models were applied to experiment, as well as several models of the cooling at the condenser end of the heat pipe. Sockeye results gave a decent match to the experimental data, with notable discrepancy in the condenser section, where experimental data indicated a significant inactive length of the heat pipe. The MARVEL microreactor was modeled through a coupled simulation of System Analysis Module (SAM) and SubChannel Module (SCM). This multiscale coupled simulation was performed as an exercise to demonstrate the compatibility and applicability of these codes for thermal-hydraulic analysis of microreactors. The coupling between the SCM and SAM codes for multiscale modeling of MARVEL, was achieved through a domain overlapping approach. In this example a transient SAM simulation provided boundary conditions to SCM, and SCM provided pressure drop to SAM.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Understanding aerosol–cloud interactions using a single-column model for a cold-air outbreak case during the ACTIVATE campaign

Marine boundary layer clouds play a critical role in Earth's energy balance. Their microphysical and radiative properties are highly impacted by ambient aerosols and dynamic forcings. In this study, we evaluate the representation of these clouds and related aerosol–cloud interaction processes in the single-column version of the E3SM climate model (SCM) against field measurements collected during the NASA ACTIVATE campaign over the western North Atlantic, as well as intercompare results with high-resolution process level models. We show that E3SM SCM reproduces the macrophysical properties of post-frontal boundary layer clouds in a cold-air outbreak (CAO) case well. However, it generates fewer but larger cloud droplets compared to aircraft measurements. Further sensitivity tests show that the underestimation of both aerosol number concentration and vertical velocity variance contributes to this bias. Aerosol–cloud interactions are examined by perturbing prescribed aerosol properties in E3SM SCM with fixed dynamics. Higher aerosol number concentration or hygroscopicity leads to more numerous but smaller cloud droplets, resulting in a stronger cooling via shortwave cloud forcing. This apparent Twomey effect is consistent with prior climate model studies. The cloud liquid water path shows a weakly positive relation with cloud droplet number concentration due to precipitation suppression. This weak aerosol effect on cloud macrophysics may be attributed to the dominant impact of strong dynamical forcing associated with the CAO. Our findings indicate that the SCM framework is a key tool to bridge the gap between climate models, process level models, and field observations to facilitate process level understanding.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1980

The Split Coefficient Matrix method for hyperbolic systems of gasdynamic equations

The Split Coefficient Matrix (SCM) finite difference method for solving hyperbolic systems of equations is presented. This new method is based on the mathematical theory of characteristics. The development of the method from characteristic theory is presented. Boundary point calculation procedures consistent with the SCM method used at interior points are explained. The split coefficient matrices that define the method for steady supersonic and unsteady inviscid flows are given for several examples. The SCM method is used to compute several flow fields to demonstrate its accuracy and versatility. The similarities and differences between the SCM method and the lambda-scheme are discussed.

Chakravarthy, S. R.↗
DOE OSTI2026

Hybrid Additive Manufacturing and Electric Field-Assisted Sintering of High-temperature Heat Exchangers via Sacrificial Channel Molds

A hybrid manufacturing approach, integrating additive manufacturing (AM) with powder methodology via electric field-assisted sintering (EFAS), was developed for the fabrication of high-temperature compact heat exchangers (CHX) from refractory metals. The methodology employed additively manufactured sacrificial channel molds (SCMs) as shapeholders for CHX channels, which were embedded in metal powders using EFAS. Following embedding, the SCMs were chemically dissolved to form the internal channel network. SCMs were fabricated using both digital light processing (DLP) and direct ink writing (DIW) from chemically reactive, calcium-based ceramic feedstocks with varying ratios of Al2O3 reinforcement. The microstructure, phase composition, and dissolution behavior of both as-printed and embedded SCMs were investigated. The shrinkage behavior of the SCMs embedded in refractory metals, as well as the interfacial characteristics between the SCMs and metal matrix, were studied. The results showed that the SCMs containing sufficient chemical reactive ceramics dissolved effectively before and after embedding. The as-printed SCMs retained the phase composition of their feedstocks, but the embedded SCMs containing calcium-based ceramics and Al2O3 exhibited the formation of calcium aluminates due to high temperature exposure during embedding. Most SCMs exhibited a cellular Al2O3 network filled with Ca-rich ceramics. Shrinkage after embedding was strongly dependent on SCM density, with lower density SCMs exhibiting greater shrinkage. A thin SCM-affected zone was observed at the metal matrix surface, characterized by increased porosity compared to the bulk matrix. This effect was attributed to infiltration of the SCM materials into powder particle boundaries under pressure, followed by their removal during dissolution. This study demonstrates the feasibility of manufacturing CHXs from hard-to-process refractory metals for use in harsh environments.

36 - MATERIALS SCIENCE↗