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At least 595 records · Page 33

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DOE OSTI2021

Powder spreading, densification, and part deformation in binder jetting additive manufacturing

Binder jetting additive manufacturing (AM) can print complex structures in economical and scalable manner. Binder jetting AM comprises of deposition and weak binding of particles, known as green part, at room temperature and subsequent binder removal and sintering densification at high temperatures. However, during the densification (i.e., sintering), the part significantly deforms due to volume shrinkage. The deformation during sintering is difficult to predict, which prevents the widespread application of this technology. In this research, powder spreading simulation using discrete element method (DEM) was performed first to capture local variations in powder bed configuration. Second, finite element method (FEM) with a phenomenological continuum constitutive model was used to predict part shrinkage during the sintering process. DEM simulation showed variations in packing density, particle segregation, formation of uneven powder bed surface, and shift in particle size distribution (PSD). The sintering simulation modeled part deformation with a reasonable accuracy of 3% for solid-state sintering and intermediate liquid phase sintering. A demonstration case with non-uniform initial packing density showed that inhomogeneous green part density and PSD should be accounted for prediction of part deformation in binder jetting AM.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Separate sensible and latent cooling: Carnot limits and system taxonomy

Energy efficiency and thermal comfort can be improved by independent control of temperature and humidity. In recent work, an emerging class of cooling systems known as separate sensible and latent cooling (SSLC) systems have demonstrated 14 to 47% energy savings, while simultaneously providing better comfort control than conventional air conditioning. In this work, SSLC is defined as using two or more cooling processes with unequal sensible heat ratio (SHR) to control temperature and humidity independently and dynamically. Fundamental efficiency limits of SSLC systems are developed for the first time, demonstrating that the Carnot efficiency for SSLC is higher than that of conventional systems. It is revealed that SSLC has particularly high potential for moderate outdoor temperatures, high sensible building loads, and drier indoor conditions. Additionally, this work proposes a classification scheme for SSLC systems, revealing an enormous number of feasible cycle permutations. This provides a framework for the important research task of developing SSLC systems that will save energy, be practical to construct, and be controllable.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Small Cells with Big Photosynthetic Productivities: Biotechnological Potential of the Picochlorum Genus

The Picochlorum genus is a distinctive eukaryotic green-algal clade that is the focus of several current biotechnological studies. It is capable of extremely rapid growth rates and has exceptional tolerances to high salinity, intense light, and elevated temperatures. Importantly, it has robust stability and high-biomass productivities in outdoor field trials in seawater. These features have propelled Picochlorum into the spotlight as a promising model for both fundamental and biotechnological research. Recently, several genetic tools, including genome editing, were developed for these algae, enabling insights into Picochlorum photophysiology and algal transformations for expanded capabilities. Here, we survey the Picochlorum genus, its genetic toolbox, recently characterized transformants, and discuss the commercial potential of Picochlorum as a salt-water photoautotrophic biocatalyst.

09 BIOMASS FUELS↗

DOE OSTI2024

High-Pressure and Temperature Effects on the Clustering Ability of Monohydroxy Alcohols

This study examined the clustering behavior of monohydroxy alcohols, where hydrogen-bonded clusters of up to a hundred molecules on the nanoscale can form. By performing X-ray diffraction experiments at different temperatures and under high pressure, we investigated how these conditions affect the ability of alcohols to form clusters. The pioneering high-pressure experiment performed on liquid alcohols contributes to the emerging knowledge in this field. Implementation of molecular dynamics simulations yielded excellent agreement with the experimental results, enabling the analysis of theoretical models. Here we show that at the same global density achieved either by alteration of pressure or temperature, the local aggregation of molecules at the nanoscale may significantly differ. Surprisingly, high pressure not only promotes the formation of hydrogen-bonded clusters but also induces the serious reorganization of molecules. This research represents a milestone in understanding association under extreme thermodynamic conditions in other hydrogen bonding systems such as water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Electronic structure and spatial inhomogeneity of iron-based superconductor FeS

Iron-based superconductor family FeX (X = S, Se, Te) has been one of the research foci in physics and material science due to their record-breaking superconducting temperature (FeSe film) and rich physical phenomena. Recently, FeS, the least studied FeX compound (due to the difficulty in synthesizing high quality macroscopic crystals) attracted much attention because of its puzzling superconducting pairing symmetry. In this work, combining scanning tunneling microscopy and angle resolved photoemission spectroscopy (ARPES) with sub-micron spatial resolution, we investigate the intrinsic electronic structures of superconducting FeS from individual single crystalline domains. Unlike FeTe or FeSe, FeS remains identical tetragonal structure from room temperature down to 5 K, and the band structures observed can be well reproduced by our ab-initio calculations. Remarkably, mixed with the 1 × 1 tetragonal metallic phase, we also observe the coexistence of √5 x √5 reconstructed insulating phase in the crystal, which not only helps explain the unusual properties of FeS, but also demonstrates the importance of using spatially resolved experimental tools in the study of this compound.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Cyclone Fani: the tug-of-war between regional warming and anthropogenic aerosol effects

Before Cyclone Amphan took place in 2020, Cyclone Fani (May 2019) is the strongest pre-monsoon cyclone in the Bay of Bengal (BOB) since 1991, killing 90 people in eastern India and Bangladesh while causing US$1.81 billion of damages. Fani developed during a period of high concentration of anthropogenic aerosols in the BOB with abnormally high sea surface temperature (SST), thereby presenting an opportunity to understand the compound effects of atmospheric aerosols and regional climate warming on a tropical cyclone. A quantitative attribution analysis was conducted using the Weather Research and Forecasting model with chemistry (WRF-Chem) run at the convection-permitting (4 km) grid spacing, accompanied by an ensemble of coarser-resolution simulations to quantify the uncertainty. The removal of post-1990 trends in the tropospheric variables and SST from WRF-Chem's initial conditions (IC) and boundary conditions (BC, including the lateral and lower boundary conditions) resulted in a reduction of cyclone precipitation by about 51% during the 5 d of April 28-May 2. The removal of tropospheric warming shows approximately twice as strong an effect on Fani (39% reduction in precipitation) as that of SST warming (22% reduction). When aerosol's direct and indirect effects were removed from the simulations, i.e., no aerosol influence on radiation and cloud microphysics, Fani initially strengthened but later weakened, as measured by geopotential height and precipitation amounts. These results suggest that aerosol and its interaction with the atmosphere acted to mitigate the strengthening effect of anthropogenic warming on Fani, but was not strong enough to entirely counteract it. Although the ensemble of coarser simulations appears to overestimate Cyclone Fani in terms of precipitation, the direction of the effects is in agreement with that obtained from the 4 km simulations. Given the increasing anthropogenic aerosols in the BOB, future attribution studies using more sophisticated dynamical aerosol models on BOB tropical cyclones are urged.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Measurement of electronic structure and surface reconstruction in the superionic Cu 2-x Te

Recently, layered copper chalcogenides Cu 2 X family (X=S, Se, Te) has attracted tremendous research interests due to their high thermoelectric performance, which is partly due to the superionic behavior of mobile Cu ions, making these compounds "phonon liquids."Here, we systematically investigate the electronic structure and its temperature evolution of the less studied single crystal Cu 2-x Te by the combination of angle resolved photoemission spectroscopy (ARPES) and scanning tunneling microscope/spectroscopy (STM/STS) experiments. While the band structure of the Cu 2-x Te shows agreement with the calculations, we clearly observe a 2×2 surface reconstruction from both our low temperature ARPES and STM/STS experiments which survives up to room temperature. Interestingly, our low temperature STM experiments further reveal multiple types of reconstruction patterns, which suggests the origin of the surface reconstruction being the distributed deficiency of liquidlike Cu ions. Our findings reveal the electronic structure and impurity level of Cu 2 Te, which provides knowledge about its thermoelectric properties from the electronic degree of freedom.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Advanced Moderator Material Handbook

High hydrogen density moderators such as metal hydrides are an important research topic within the DOE NE Microreactor Research, Development, and Deployment (RD&D) Program due to their ability to retain hydrogen to much higher temperatures than other hydrogenous media. This class of moderators, which includes yttrium dihydride (YH 2 ), thermalizes neutrons in the system such that the overall fuel mass or the required uranium enrichment in the system can be significantly reduced. Knowledge of material properties, both in the as-fabricated and irradiated state, are important to understanding moderator performance during steady-state and transient reactor operation. Provided in this document is the Advanced Moderator Material Handbook, which provides a detailed summary of the literature data on yttrium dihydride, thermomechanical and other property data, and a critical evaluation of that data. This handbook also provides a description of ongoing experiments to understand in-reactor performance, such as irradiations in ATR, as well as nuclear data from an integral critical experiment at NCERC. The majority of this report focuses on measured values but also includes some modeling results for comparison where applicable.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Advanced Moderator Material Handbook (FY22 Rev. 2)

High hydrogen density moderators such as metal hydrides are an important research topic within the DOE NE Microreactor Research, Development, and Deployment (RD&D) Program due to their ability to retain hydrogen to much higher temperatures than other hydrogenous media. This class of moderators, which includes yttrium dihydride (YH 2 ), thermalizes neutrons in the system such that the overall fuel mass or the required uranium enrichment in the system can be significantly reduced. Knowledge of material properties, both in the as-fabricated and irradiated state, are important to understanding moderator performance during steady-state and transient reactor operation. This document provides a detailed summary of the literature data on yttrium dihydride, thermomechanical and other property data, and a critical evaluation of that data. This handbook also provides a description of ongoing experiments to understand in-reactor performance, such as irradiations in ATR, as well as nuclear data from an integral critical experiment at NCERC. This report focuses on measured quantities but also includes some modeling results for comparison where applicable.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Development of Multimaterial Graded Structure from Superalloys to Refractory Alloys

This research focused on developing hybrid microstructures for extreme environments where zone-specific performance is essential. Traditional structural applications rely on single alloy compositions, often requiring compromises in cost, corrosion resistance, or high-temperature stability, while dissimilar welding leads to abrupt material transitions and potential mechanical weaknesses. By employing a combinatorial approach, this study enabled a gradual transition of chemistries across components, allowing site-specific tailoring of microstructures. Leveraging additive manufacturing’s flexibility, this concept facilitated multi-material alloying and optimized fabrication strategies, unlocking new capabilities in high-performance applications while reducing manufacturing costs.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Development of Multimaterial Graded Structure from Superalloys to Refractory Alloys

36 MATERIALS SCIENCE↗

DOE OSTI2025

Processability and Material Behavior of NiTi Shape Memory Alloys Using Wire Laser-Directed Energy Deposition (WL-DED)

Utilizing additive manufacturing (AM) techniques with shape memory alloys (SMAs) like NiTi shows great promise for fabricating highly flexible and functionally superior 3D metallic structures. Compared to methods relying on powder feedstocks, wire-based additive manufacturing processes provide a viable alternative, addressing challenges such as chemical composition instability, material availability, higher feedstock costs, and limitations on part size while simplifying process development. This study presented a novel approach by thoroughly assessing the printability of Ni-rich Ni55.94Ti (Wt. %) SMA using the wire laser-directed energy deposition (WL-DED) technique, addressing the existing knowledge gap regarding the laser wire-feed metal additive manufacturing of NiTi alloys. For the first time, the impact of processing parameters—specifically laser power (400–1000 W) and transverse speed (300–900 mm/min)—on single-track fabrication using NiTi wires in the WL-DED process was examined. An optimal range of process parameters was determined to achieve high-quality prints with minimal defects, such as wire dripping, stubbing, and overfilling. Building upon these findings, we printed five distinct cubes, demonstrating the feasibility of producing nearly porosity-free specimens. Notably, this study investigated the effect of energy density on the printed part density, impurity pick-up, transformation temperature, and hardness of the manufactured NiTi cubes. The results from the cube study demonstrated that varying energy densities (46.66–70 J/mm3) significantly affected the quality of the deposits. Lower to intermediate energy densities achieved high relative densities (>99%) and favorable phase transformation temperatures. In contrast, higher energy densities led to instability in melt pool shape, increased porosity, and discrepancies in phase transformation temperatures. These findings highlighted the critical role of precise parameter control in achieving functional NiTi parts and offer valuable insights for advancing AM techniques in fabricating larger high-quality NiTi components. Additionally, our research highlighted important considerations for civil engineering applications, particularly in the development of seismic dampers for energy dissipation in structures, offering a promising solution for enhancing structural performance and energy management in critical infrastructure.

Dabbaghi, Hediyeh↗

DOE OSTI2024

Isolated Single Metal Atoms Supported on Silica for One Step Non-Oxidative Methane Upgrading to Hydrogen and Value-Added Hydrocarbons

Natural gas in the United States offers substantial economic opportunities due to its abundance but its transportation is challenging because its primary component, methane (CH 4 ), does not liquefy at ambient temperature and typical pressures. As a result, a significant portion of natural gas is either used for heat, flared in remote locations, or remains unutilized, presenting a lost economic opportunity and an environmental harm. Converting natural gas to larger hydrocarbons in an economically competitive manner would enable transportation of products and further boost the economy and reduce environmental footprint. Our research goal is to enable efficient non-oxidative methane conversion (NMC) via catalyst innovation to convert CH 4 in one-step to olefins and aromatics and hydrogen (H 2 ) co-product. The catalysts are made of supported single metal atoms and operated at medium-high temperatures. The single metal atoms achieve methane activation by heterogeneous surface dehydrogenation to generate a hydrocarbon pool and importantly limit coke formation. The integration of novel single atom catalysts in a short contact time microreactor enable unprecedented NMC performance that could lead to economically-feasible, distributed natural gas upgrading by advanced manufacturing and process intensification. Our innovated catalyst and reactor technology promise to tap into previously uneconomic natural gas resources, such as stranded, vented, and flared methane.

03 NATURAL GAS↗

DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Development of a Data Platform for High-Temperature Gas-cooled Reactor (HTGR) Nuclear Energy University Program (NEUP) Thermal-Fluid Experiments

Since the U.S. Department of Energy (DOE)’s Office of Nuclear Energy (NE) initiated the Nuclear Energy University Program (NEUP) in 2009, a total of 30 NEUP projects focused on High-Temperature Gas-cooled Reactor (HTGR) thermal-fluid experiments were funded up to fiscal year (FY) 2021. This represents a total DOE investment of approximately $23M over the 12-year period, covering thermal fluid phenomena important to both pebble bed and prismatic HTGR designs. The NEUP projects have produced a large amount of high-quality experimental and computational data that were published in final project reports, journal articles, dissertations, and conference proceedings, but in most cases the actual data sets and supporting information such as facility and instrumentation descriptions were not publicly disseminated to the HTGR community. To the authors’ best knowledge, a data platform that organizes and summarizes these NEUP-funded projects for HTGR research does not currently exist. To improve access to this HTGR validation data and optimize the return on the significant investment made by DOE, the Advanced Reactor Technologies (ART) Gas-Cooled Reactor (GCR) program started a survey of completed and ongoing HTGR NEUP projects with the aim of developing a public-access data platform that can be used to retrieve computational fluid dynamics (CFD) and system code validation data and guide future NEUP investments. This paper summarizes the status of the current ART-GCR database, provides an overview of the NEUP-funded HTGR-related research projects from FY2009 to FY2021 and identify validation knowledge gaps still existing in HTGR thermal-fluid research.

42 ENGINEERING↗

DOE OSTI2020

Charge ordering in superconducting copper oxides

Abstract Charge order has recently been identified as a leading competitor of high-temperature superconductivity in moderately doped cuprates. We provide a survey of universal and materials-specific aspects of this phenomenon, with emphasis on results obtained by scattering methods. In particular, we discuss the structure, periodicity, and stability range of the charge-ordered state, its response to various external perturbations, the influence of disorder, the coexistence and competition with superconductivity, as well as collective charge dynamics. In the context of this journal issue which honors Roger Cowley’s legacy, we also discuss the connection of charge ordering with lattice vibrations and the central-peak phenomenon. We end the review with an outlook on research opportunities offered by new synthesis methods and experimental platforms, including cuprate thin films and superlattices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

High-Resolution WRF-Based Downscaling of Earth System Model Projections for Energy Applications across CONUS

Evaluating energy resources under future scenarios requires meteorological information that adequately resolves regional-scale variability and is suitable for regional energy system studies. Although Earth system model (ESM) outputs provide essential large-scale context, their coarse resolution and inherent biases limit direct use in energy system applications. This work presents a high-resolution dynamical downscaling framework using the Weather Research and Forecasting (WRF) model to generate energy-relevant regional fields for future scenarios over the contiguous United States (CONUS). The framework first identifies an optimal WRF configuration through sensitivity experiments, then evaluates raw and bias-corrected ESM initial and boundary conditions, with soil moisture and soil temperature bias correction implemented as an integral component of the bias-corrected ESM atmospheric forcing prior to WRF dynamical downscaling to improve land-atmosphere interactions. Simulations performed at 4-km resolution show that uncorrected ESM forcing leads to systematically dry and cold soil states, which propagate into elevated near-surface air temperature and solar irradiance biases, particularly during summer for the period 2000-2014. Incorporating bias-corrected atmospheric forcing together with soil state bias correction substantially reduces these errors and improves the representation of surface energy processes in WRF simulations. The results highlight the importance of bias-aware initialization strategies in high-resolution dynamical downscaling for future energy system analysis and planning.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Synthesis of La 2–x Sr x CuO 4 films via atomic layer-by-layer molecular beam epitaxy

Atomic layer-by-layer molecular beam epitaxy (ALL-MBE) is a sophisticated technique to synthesize high-temperature superconductor (HTS) materials. ALL-MBE produces single-crystal HTS films with atomically smooth surfaces and interfaces, as well as precise multilayer heterostructures engineered down to a single atomic layer level. This enables the fabrication of tunnel junctions, nanowires, nanorings, and other HTS devices of interest. Our group has focused on ALL-MBE synthesis and materials science of La 2–x Sr x CuO 4 (LSCO), a representative HTS cuprate. In the past two decades, we have synthesized over three thousand LSCO thin films and characterized them by a range of analytical techniques. Here, we present in full detail a systematic process for the synthesis and engineering of atomically perfect LSCO films. The procedure includes the preparation of substrates, calibration of the elemental sources, the recipe for ALL growth of LSCO films without any secondary-phase precipitates, post-growth annealing of the films, and ex situ film characterization. This report should aid replication and dissemination of this technique of synthesizing single-crystal LSCO films for basic research as well as for HTS electronic applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗