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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
DOE OSTI2020

Panel Session 79: Challenges and Lessons Learned in Radwaste Packaging, Transportation, Compliance, and Receipt

This panel focused on challenges and lessons learned in radioactive waste packaging, transportation, compliance, and receipt for fabricators of radioactive waste packaging. World-wide companies are urged to participate. Participants provided their perspectives and suggestions on how to increase efficiencies through eliminating inconsistencies between specifications and other requirements to provide products at a reasonable cost and enhance communication to enable better service. Panelists with presentations: PACTEC (Bill Smart); Waste Packaging Strategy and Challenges at Whiteshell (Miles Smith); Challenges and Lessons Learned in Radwaste Packaging, Transportation, Compliance and Receipt (Dan Payne)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Microwave-assisted synthesis of iron sulfide motifs for electrochemical applications

Abstract The syntheses of FeS 2 and Fe 3 S 4 nanomaterials were optimized using a novel facile, surfactant-free, and microwave-assisted, one-pot synthesis method, run under ambient and reasonably mild reaction conditions. Synthetic parameters, such as metal precursor salt identity, reaction time, reaction temperature, metal:sulfur molar ratios, and solvent combinations, were all systematically investigated and optimized. A series of FeS 2 (pyrite) samples was initially fabricated using thioacetamide (TAA) as the sulfur precursor to generate a distinctive, uniform octahedra-based morphology. Switching the sulfur precursor from TAA to L-cysteine resulted in a corresponding transformation in not only chemical composition from FeS 2 to an iron thiospinel structure, Fe 3 S 4 (otherwise known as greigite), but also an associated morphological evolution from octahedra to nanosheet aggregates. The study of these materials has enabled crucial insights into the formation mechanisms of these materials under a relatively non-conventional microwave-assisted setting. Furthermore, in separate experiments, multi-walled carbon nanotubes (MWNTs) and graphene were added in with underlying metal sulfide species to create conductive Fe–S/MWNT composites and Fe–S/graphene composites, respectively. The method of addition of either MWNTs or graphene was also explored, wherein an ‘ ex-situ ’ synthetic procedure was found to be the least disruptive means of attachment and immobilization onto iron sulfide co-reagents as a means of preserving the latter’s inherent composition and morphology. The redox acidity for the parent material and associated composites demonstrates the utility of our as-developed synthetic methods for creating motifs relevant for electrochemical applications, such as energy storage.

25 ENERGY STORAGE↗
DOE OSTI2020

Life-cycle environmental impacts of single-junction and tandem perovskite PVs: a critical review and future perspectives

For new technologies, such as perovskite solar cells (PSC), life cycle analysis (LCA) offers a fundamental framework for examining potential environmental, energy and health impacts and mitigation options before large-scale commercialization and for guiding improvements in development and production that further reduce their environmental footprint. However, credible LCA studies require actual process-based material, energy and emissions data, which may not exist before the technologies are commercially produced. Thus, the perovskite LCA literature is based on linear extrapolations of laboratory data. In this paper we critically reviewed the PSC LCA literature, explain the reasoning for a wide divergence of results, and determined which data apply to scalable industrial production, materials and processes. Our investigation probed into the formulation of each layer of a PSC device, and its potential for industrial scale fabrication. We found that electricity use is the main contributor to reported LCA results, explaining the large difference, ranging from 7.78 kWh to 1,460 kWh/m –2 , among various studies. Subsequently, we identified and discuss methodological errors in some of these estimates. In terms of life-cycle toxicity most of the reviewed LCA studies do not attribute any major overall toxicity impact to the presence of lead in the PSC devices. We also reviewed and critiqued studies describing “worst-case” scenarios of accidental release of lead into the environment, and, in spite of statements in those studies, we found them to be inconclusive. Lastly, we discussed end-of-life (EoL) management options for resource recovery and for minimizing environmental impacts.

14 SOLAR ENERGY↗
DOE OSTI2020

Characterization of high-purity germanium detectors with amorphous germanium contacts in cryogenic liquids

For the first time, planar high-purity germanium detectors with thin amorphous germanium contacts were successfully operated directly in liquid nitrogen and liquid argon in a cryostat at the Max-Planck-Institut für Physics in Munich. The detectors were fabricated at the Lawrence Berkeley National Laboratory and the University of South Dakota, using crystals grown at the University of South Dakota. They survived long-distance transportation and multiple thermal cycles in both cryogenic liquids and showed reasonable leakage currents and spectroscopic performance. Also discussed are the pros and cons of using thin amorphous semiconductor materials as an alternative contact technology in large-scale germanium experiments searching for physics beyond the Standard Model.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Metal (Cu,Al)/CNT Composite Wires for Energy Efficient Motors

This report summarizes the main results of research project on Metal/CNT nanocomposites conducted at University of Central Florida (UCF). It should be noted that the project was budgeted for three years, but the budget period 3 was unfortunately not funded and conducted in COVID19 pandemic years due to many reasons. The demonstration plan on the small motors was also removed according to the discussion with the DOE program manager. All research activities were focused on the (Cu,Al)/CNT material development and wire extrusion. Existing methods to fabricate Metal/CNTs were usually suffering from agglomeration of CNTs due to their density and stiffness differences. A new method is studied by the UCF research team, where CNTs are surface treated firstly, then coated with pure metals (i.e., Al, Cu, and Nickle). The metal encapsulation on CNT is expected to significantly improve the interfacial bonding between CNTs and the intimated metal matrices. The coated CNT powders were used to make sample materials through sintering, then a customized wire extrusion process was employed to fabricate wires. Measurement of material property improvements in mechanical strength, thermal conductivity, and electrical conductivity were conducted on both cylinder samples and extruded wires. In addition to the sintering process, casting on metal coated CNT powder was also investigated. The best results we achieved are summarized as follows. (1) The measured thermal conductivity of Al/CNT composite made with Ni-encapsulated CNTs and pure Al powders is about 85% better than that of pure aluminum fabricated. The measured electrical conductivity of fabricated Al/CNT is about 14-20% better than that of pure aluminum. (2) The measured electrical conductivity of Cu/CNT is about 14.5% better than that of pure copper fabricated. (3) The mechanical strengths of both Cu/CNT and Al/CNT (with about 1% wt. CNTs) are 70% better than pure metals although losing some material ductility. (4) Two-stage wire extrusion at high temperatures were designed and successfully conducted to fabricate wires of Metal/CNTs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluation of the Self Retrieval Augmented Generation Technique on Common Security Advisory Framework Data

This small experimental report evaluates a variation of Retrieval Augmented Generation (RAG), called Self-RAG. This method uses a generative language model that incorporates retrieved facts into its generation and is explicitly trained to be able to determine whether retrieved information is enough to answer the input query, with a user-defined threshold for confidence. We performed an experiment using data from the publicly available CISA Common Security Advisory Framework (CSAF) repository (https://github.com/cisagov/CSAF) as the database of facts to be used in retrieval. Qualitative results from the experiment demonstrate that the Self-RAG method has some ability to provide reasonable answers to queries that are in the dataset and will often ignore irrelevant information when asked outside of domain questions (e.g., general facts). In settings with deliberately confusing questions (the question is within domain, but asks about a fabricated advisory), it was able to refuse 40% of the time without further adjustments to the original framework. While this performance is not sufficient for current practical use, further improvements to data formatting, disambiguating results, and leveraging threshold values could improve performance significantly. However, evaluating this will require more extensive evaluations on larger datasets and potentially better models.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Catalyst-containing oxygen transport membrane

A method is described of producing a catalyst-containing composite oxygen ion membrane and a catalyst-containing composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln 1−x A x ) w Cr 1−y B y O 3−δ and a doped zirconia. Adding certain catalyst metals into the fuel oxidation layer not only enhances the initial oxygen flux, but also reduces the degradation rate of the oxygen flux over long-term operation. One of the possible reasons for the improved flux and stability is that the addition of the catalyst metal reduces the chemical reaction between the (Ln 1−x A x ) w Cr 1−y B y O 3−δ and the zirconia phases during membrane fabrication and operation, as indicated by the X-ray diffraction results.

Lu, Zigui↗
DOE OSTI2021

Similarity properties in capacitive radio frequency plasmas with nonlinear collision processes

Abstract Similarity laws (SL) are essential for correlating the characteristics of plasmas at different dimensional scales, which have been validated for radio frequency (rf) discharges at low pressure but under limited conditions. In this work, we evaluate the effects of nonlinear collisions (e.g. stepwise ionization) on the similarity properties in capacitive rf discharges in argon across a wide range of pressure regimes via fully kinetic particle-in-cell simulations. The SL scalings of fundamental discharge parameters, e.g. the electron power absorption and electron energy probability function, are examined with and without nonlinear collisions, respectively. Without the nonlinear collisions, the similarity scalings are found to be rigorously valid. When the nonlinear collisions are considered, the similarity properties in rf discharges still exist approximately, which indicates that the violations caused by the nonlinear collisions are still minor in the studied cases. The reasons for the effectiveness of SL scalings with nonlinear collision processes are also discussed. The results from this study confirmed the validity of similarity transformations with more complex reaction kinetics, which may promote the applicability of the SL scalings for the design and fabrications of plasma devices.

Physics↗
DOE OSTI2021

Investigations Towards Ultra-Low Cost Nb 3 Sn SRF Fabrication via Melt Casted Bronze Route Processing

Here, a novel approach to fabricating Nb 3 Sn SRF cavities and other RF components using an ultra-low-cost melt casting fabrication process has been investigated. This simple, low cost melt casting technique has the potential to be used to fabricate nearly any superconducting Nb3Sn structure using either the Bronze Route (BR), Internal Tin (IT), External Tin (ET) processes as well as normal conducting pure copper (Cu) cavities. Most of the heat treated samples that were examined using SEM/EDX seemed to show a reasonable correlation of T c onset and transition width (ΔT c ) of the ingots initial/starting Sn content to the desired stoichiometric Nb 3 Sn phase, where the lower starting Sn content coupons resulted in lower T c 's with broader transition widths and the higher starting Sn coupons resulted in higher T c 's with narrower ΔT c ’s. The best samples had T c onsets ~17-18 K and ΔT c 's < 2 K. Two samples were further tested for RF surface resistance (R s ) and Quality Factor (Q) at JLAB. Here, these RF measurements were performed at 7.4 GHz using a calorimetric technique and showed two transitions, one at ~ 8 K and another at ~ 14 K; values of R s were at least two orders of magnitude higher than similar high quality Nb 3 Sn films directly deposited substrates by JLAB and with another superconducting transition close to the superconducting transition temperature of niobium. Substantial improvements in the processing variables ranging from higher quality of the initial ingots with higher Sn content, to better electropolishing and reaction heat treatment regimens will be necessary to realize improved RF performance metrics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Materials Science of the Interstitial Doping Process

Particle accelerators are an increasingly important tool for frontier science. Growing initial and operating costs are a significant barrier for upgrades and for new machines. While everything matters, the major cost contributor is the SRF cavities and their ancillary facilities (e.g., cryoplant). Accordingly, the accelerator science community devotes much R&D effort to improving their energy efficiency (increased Q o ) and gradient (E acc ). While improved gradient is at the forefront for certain machines (ILC), improved quality factor has broader impact, benefitting all SRF applications. An important opportunity for accelerator science and technology to move forward arose in the course of building the LCLS-II, the second generation Linac Coherent Light Source at SLAC. At more or less the same time, researchers at Fermilab discovered that introducing a small amount of nitrogen to the niobium surface could improve the mid-range quality factor as much as three-fold. A firm resolution of how nitrogen confers its benefit attracts much current research interest. The key elements of the “nitrogen doping” process were vacuum bake at 800 °C, brief exposure to mTorr of nitrogen at several hundred degrees followed by electropolish (EP) to remove several microns from the surface to eliminate unwanted nitrides: While the process as a whole was novel, the comprising unit operations are familiar to the accelerator community. It was judged reasonable to adopt it as a cost-reduction technology for LCLS-II. Researchers carried out a program of varying process parameters and measuring performance in single-cell cavities, leading to a consensus stable protocol for the project. The transition to vendor fabrication and multiple niobium sources has presented unforeseen challenges of performance variation evidently not connected to anything that could be incorporated in a purchase specification. Moving beyond the high temperature N-doping process above, researchers reported a simplified process consisting entirely of tens of hours anneal in a N atmosphere at low temperatures (~120°C – 160°C) after 800 °C UHV bake. These processes typically yield a few-nm doped layer while the high temperature process yields at least a few to many micron doped layer. Even more recently, oxygen has been used to dope instead of nitrogen which leaves a few-µm O-alloyed layer upon vacuum annealing for 300 °C for ~3 hours. The investigation of these materials is just beginning, but the process simplification they may offer is surely attractive. The very low quantity of material that appears to be significant in the “infusion” process indicates the need for very careful control of gas species available for diffusion into the surface during low temperature treatment, both for process control and research to characterize the underlying dynamics. Oxygen alloying offers the further opportunity to utilize the decomposition of the surface native oxide as the dopant source. It is necessary to understand and (thus) manage this process. We have been supported by the Department of Energy Offices of High Energy Physics and Nuclear Physics to pursue this goal.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Scaling open-weight large language models for hydropower regulatory information extraction: A systematic analysis

Information extraction from regulatory and technical documents using large language models (LLMs) involves practical trade-offs between extraction quality and computational cost. We evaluate eight open-weight LLMs spanning 0.6B–70B parameters on hydropower licensing documents and report deployment-oriented evidence under a unified extraction schema and evaluation protocol. Across the model set, we observe clear scale-dependent trends in both baseline extraction quality and the effectiveness of reflective reasoning (self-checking) under our fixed-prompt, no-augmentation setting. Mid-scale models often provide a favorable balance of accuracy and efficiency, whereas the smallest models show limited or inconsistent gains from the reasoning variants tested. Larger models achieve the highest overall F1 scores but incur substantially greater compute and infrastructure requirements. We further find that reliability failure modes can distort conventional metrics in this domain: in particular, high recall can coincide with systematic extraction errors when models fabricate values for fields that are absent from the source text, underscoring the importance of conservative null handling and evidence-grounded evaluation. Overall, our study provides a reproducible resource–performance comparison for open-weight LLM-based extraction in hydropower regulatory documentation and offers practical guidance for model selection under different deployment constraints.

Evaluation protocol↗
DOE OSTI2025

Production of Creep-Resistant FeCrAl-ODS

Four ODS FeCrAl alloys with base alloy composition Fe-16Cr-4Al-2Mo-0.2Y (wt.%) were mechanically alloyed with minor additions of CeO 2 and Y 2 O 3 additions and were successfully extruded into rectangular-shaped bars. Two oxide compositions were explored, which were designated NC with oxide addition of 0.5CeO 2 plus 0.2Yin solution of the base alloy powder and PC with additions of 0.5CeO 2 and 0.7Y 2 O 3 to elevate the O level. The microstructure of both alloys revealed by SEM and EBSD to consist of very small grains with sizes of ~450-520 nm and weak texture components. Sub-size tensile specimens fabricated from both alloys were tensile tested from room temperature to 800ºC. The results for both alloys from room temperature to 400ºC showed very high strengths, but low ductilities, especially uniform strain. From 500ºC to 800ºC, the strengths decreased rapidly, and the ductilities increased significantly. The reason for the rapid decreases in tensile strengths above 500ºC for both alloys is not clear, but will require advanced characterization techniques including atom probe tomography, to determine the size and number density of the nano-size oxide particles, and TEM/EFTEM, for investigating the dispersion of nano-size oxide particles on grain boundaries to assess the Zener grain boundary pinning effect, which will hinder grain coarsening at high temperatures that may enhance the Hall Petch strengthening mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Building high throughput permissioned blockchain fabrics: challenges and opportunities

Since the introduction of Bitcoin---the first widespread application driven by blockchains---the interest in the design of blockchain-based applications has increased tremendously. At the core of these applications are consensus protocols that securely replicate client requests among all replicas, even if some replicas are Byzantine faulty. Unfortunately, these consensus protocols typically have low throughput, and this lack of performance is often cited as the reason for the slow wider adoption of blockchain technology. Consequently, many works focus on designing more efficient consensus protocols to increase throughput of consensus. We believe that this focus on consensus protocols only explains part of the story. To investigate this belief, we raise a simple question: Can a well-crafted system using a classical consensus protocol outperform systems using modern protocols? In this tutorial, we answer this question by diving deep into the design of blockchain systems. Further, we take an in-depth look at the theory behind consensus, which can help users select the protocol that best-fits their requirements. Finally, we share our vision of high-throughput blockchain systems that operate at large scales.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Conventionally sol-gel spray-on transducers require a high-temperature (> 700 ◦C) sintering process; however, this process can affect the microstructure of the substrate material. For mechanical elbows and valves utilized for fluid transport in the energy sector, the components are designed to have a specific microstructure, and deviations from these specifications can create weak points in the system. For this reason it is important to investigate how the temperature of the deposition process affects the substrate. This paper investigates the effect of high-temperature and low-temperature (< 150 ◦C) processing conditions on the surface composition of the substrate. Furthermore, the resultant transducers from high- and low-temperature fabrication processes are compared to determine if a low-temperature processing method is feasible. For these studies a sol-gel spray-on process is employed to deposit piezoelectric ceramics onto a stainless-steel 316L substrate. Energy-dispersive X-ray spectroscopy is utilized to determine the composition of the substrate surface before and after transducer deposition. Results indicate that the high-temperature processing conditions may alter the surface composition of the metal due to a diffusion of the metal into the ceramic, which results in a metal surface that is bonded to the ceramic. Furthermore, it is shown that low-temperature processing of spray-on transducers is a viable method for transducer fabrication where the resultant transducers meet the industry minimum requirement of 30 dB signalto-noise ratio. In parallel simulation calculations, finite-element method (FEM) studies were performed to model the adhesive strength of the low-temperature processed transducer to the substrate surface. Comparisons between the simulations and experiments suggest that the bond strength is much greater than the commercial gel bonds and closer to hardened epoxy glue bonds. These results indicate that spray-on transducers fabricated under lowtemperature processing conditions are a viable solution for leave-in-place monitoring of structures.

M. Sinding, Kyle↗
DOE OSTI2023

Investigating boosted decision trees as a guide for inertial confinement fusion design

Inertial confined fusion experiments at the National Ignition Facility have recently entered a new regime approaching ignition. Improved modeling and exploration of the experimental parameter space were essential to deepening our understanding of the mechanisms that degrade and amplify the neutron yield. The growing prevalence of machine learning in fusion studies opens a new avenue for investigation. Here in this paper, we have applied the Gradient-Boosted Decision Tree machine-learning architecture to further explore the parameter space and find correlations with the neutron yield, a key performance indicator. We find reasonable agreement between the measured and predicted yield, with a mean absolute percentage error on a randomly assigned test set of 35.5%. This model finds the characteristics of the laser pulse to be the most influential in prediction, as well as the hohlraum laser entrance hole diameter and an enhanced capsule fabrication technique. We used the trained model to scan over the design space of experiments from three different campaigns to evaluate the potential of this technique to provide design changes that could improve the resulting neutron yield. While these data-driven model cannot predict ignition without examples of ignited shots in the training set, it can be used to indicate that an unseen shot design will at least be in the upper range of previously observed neutron yields.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

A New Offering for the Seaman Status Labyrinth - Seaman Status for Nuclear Reactor Operators on Floating Nuclear Power Plants

Floating nuclear power plants present a unique operating environment for land-based nuclear reactor operators. Traditionally located in the control room of a nuclear power plant on land, development of floating nuclear power plants exposes the traditional land-based employees to the marine environment. With the extension of nuclear power generation facilities into the maritime domain, do nuclear reactor operators working on a floating nuclear power plant qualify as seaman under maritime law? Applying existing maritime law, the answer is no, a nuclear reactor operator who operates the nuclear reactor on a floating nuclear power plant does not qualify as a seaman because their work is not in support of the mission of the vessel and the reactor is not connected to a vessel because a floating nuclear power plant is not a vessel. Applying the analysis developed by the Supreme Court in Chandris v. Latsis and the recent Sanchez v. Smart Fabricators of Texas, L.L.C. en banc decision by the Fifth Circuit, a nuclear reactor operator on a floating nuclear power plant does not qualify for seaman status under the Jones Act because their function supports the operation of the reactor and the structure on which the reactor resides does not meet the reasonable person standard established in Lozman v. City of Riviera Beach. Further, existing case law highlights that rendering a structure practically impossible to move eliminates the structure from consideration as a vessel. Because a floating nuclear power plant may be anchored at a seaport or anchored offshore but connected via transmission cables and protected by physical protection barriers, a floating nuclear power plant, with no current means of propulsion is rendered a power plant on water, which is its true function. Recognizing that technological change may alter the conclusion presented in this Article, current designs and structures that exist illustrate the intersection between nuclear and maritime law and the ever-evolving concepts that underpin seamen status in maritime law.

Fialkoff, Marc↗
DOE OSTI2024

UNCERTAINTIES FOR IN-REACTOR TESTING OF TRITIUM LOADED GETTERS WITH TEMPERATURE CONTROL

The fourth experiment in TPBAR Materials Irradiation Separate-Effects Test (TMIST) series (TMIST-4) is planned to experimentally determine the effect of neutron irradiation on the equilibrium vapor pressure of tritium over a tritium loaded Nickel-Plated Zirconium (NPZ) getter in a simulated TPBAR service environment. This pressure will be used to estimate the tritium permeation rate. In the thermal design in the TMIST-4, two evaluations are required. 1) The cladding temperature is calculated to estimate the feasibility of detecting potential irradiation enhancement of the partial pressure for an NPZ getter. This work is required to obtain a precise cladding temperature for measurement of a low tritium partial pressure. This work has been completed and indicated that the required/target cladding temperatures based on the TMIST-4 test plan can be satisfied under the test condition range by modifying the capsule component shapes and inserting a thermally conductive metal sleeve. 2) The evaluation of uncertainties associated with the test design and operation is performed. This includes fabrication tolerances, and power and nuclear operating conditions. These factors will impact the component temperatures inside capsules and resulting the tritium partial pressure. The tritium permeation rate is a function of temperature and tritium partial pressure. The prediction of tritium permeation rates affects the feasibility of obtaining measurement resolutions required to reach reasonable conclusion for potential irradiation enhanced performance. This work will investigate the uncertainties.

TTP, TPBAR, TMIST-4, TPBAR Materials Irradiation S↗
DOE OSTI2022

Final Scientific/Technical Report-FREE-piston Zero Emissions Refrigerator (FREEZER)

The FREE-piston Zero Emissions Refrigerator (FREEZER™) is a natural refrigerant Stirling-cycle cooler developed by AMSC in partnership with Heatcraft, targeted as a replacement refrigeration system for walk-in coolers or freezers found commonly in restaurants, convenience stores, supermarkets, etc. The FREEZER™, combined with a closed-loop CO2 heat-transfer system, had the goal to provides an efficient (Target COP = 1.4), zero ODP (Ozone Depletion Potential) and near zero GWP (Global Warming Potential) refrigeration solution with no synthetic, flammable, or toxic refrigerants. Other near zero GWP refrigeration systems do not exist at the scale and performance level of FREEZER. ARPA-E Continuation Funding enabled the design and fabrication of one Advanced Development Unit (ADU) cooler and two Field Test Unit (FTU) coolers, and a new revised Field Test Unit (new FTU). Heatcraft was to extensively test the various coolers at their facilities, which closely simulate real-world conditions. The original plan was to install and operate FREEZER FTUs alongside a traditional cooling solution at one or more customer locations to obtain data on direct performance comparisons with existing commercial refrigeration systems. Success in this FREEZER refinement and field-test project will establish the basis for a new class of environmentally friendly refrigeration systems that will revolutionize the industry. The hardware developed under the program is shown below in Figure 1. Five Stirling-cycle machines were built within the program, with a sixth cooler still under construction. The original DU and the ADU coolers met the performance target with a coefficient of performance (COP) of 1.2. The FTU was underperforming during the initial tuning of the free-piston Stirling cycle dynamics when there was a catastrophic failure of the fasteners on pressure boundary. This caused a pause to the program while the failure mechanism was investigated. The root cause was an inadequate flange design that allowed an excessive cyclic loading on the fasteners, leading to a fatigue failure. It was determined that existing FTU design could not be reasonably salvaged in a safe manner, and that fact, combined with the lower-than-expected performance of the new experimental heat exchanger modules lead to the design of the “new FTU” with a more conventional shell-and-tube heat exchanger design which should get close to the design target COP of 1.4, but have a higher overall machine cost. The program ran out of time before the fabrication of the new FTU was completed, but AMSC is still working on the cooler, with the majority of the parts fabricated, and hopes to have the unit under test sometime in early 2022, after which it will be shipped to Heatcraft for additional testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗