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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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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Characterizing the Sensitivity of 40 GHz TES Bolometers for BICEP Array

The BICEP/Keck (BK) experiment aims to detect the imprint of primordial gravitational waves in the cosmic microwave background polarization, which would be direct evidence of the inflation theory. While the tensor-to-scalar ratio has been constrained to be $r_{0.05}<0.06$ at 95% c.l., further improvements on this upper limit are hindered by polarized galactic foreground emissions and removal of gravitational lensing polarization. The 30/40 GHz receiver of the BICEP Array (BA) will deploy at the end of 2019 and will constrain the synchrotron foreground with unprecedented accuracy within the BK sky patch. We will show the design of the 30/40 GHz detectors and test results summarizing its performance. The low optical and atmospheric loading at these frequencies requires our TES detectors to have low saturation power in order to be photon noise dominated. To realize the low thermal conductivity required from a 250 mK base temperature, we developed new bolometer leg designs. We will present the relevant measured detector parameters: $G, T_c, R_n, P_{sat}$, and spectral bands, and noise spectra. We achieved a per bolometer NEP including all noise components of 2.07×10 -17 W/$\sqrt{Hz}$, including an anticipated photon noise level 1.54×10 -17 W/$\sqrt{Hz}$.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Iron-Based Chalcogenide Spin Ladder BaFe2 X 3 (X = Se,S)

The relevance of magnetic, structural, orbital, and charge degrees of freedom in the iron-based superconductors (FeSCs) and related materials occupies a central focus in condensed matter physics. While the majority of iron-based materials exhibit the same two-dimensional iron square lattice structural motif, a family of AFe2X3 (X = Se,S) compounds introduces a quasi-one-dimensional (1D) ladder motif, which resembles the two-legged spin ladder copper oxide materials. Furthermore, unlike most parent compounds of FeSCs, the members of this spin ladder family are insulators. Recently, a superconducting transition has been observed under pressure with Tc up to 24 K, similar to the pressure-induced superconductivity in the copper oxide ladder Sr14-xCaxCu24O41 material, stimulating much interest. Here, we review the magnetic, structural, and electronic properties in this family, particularly in the BaFe2X3 series tuned by pressure and by chemical substitution. The established pressure-temperature (P-T) and carrier concentration-temperature (x-T) phase diagrams in related materials provide useful information to extend the variety of high-temperature superconductors and compare with other FeSCs. We also review some essential information about analogous square lattice FeSCs.

Wu, S↗
DOE OSTI2024

Single-atom materials boosting wearable orthogonal uric acid detection

Abstract Uric acid (UA) is a vital biomarker for the diagnosis and management of various health conditions, including cardiovascular diseases, gout, kidney disorders, metabolic syndrome, and wound healing. Despite significant advances in wearable sensor technology, challenges persist in developing wearable sensors that are capable of maintaining high sensitivity, selectivity, and stability. In this study, we present an epidermal sensing platform enhanced with single-atom materials (SAMs) designed for flexible and orthogonal electrochemical detection of UA. We designed and synthesized an SAM with Fe-N 5 active sites to boost the electrochemical sensing signals, integrating it with laser-engraved graphene (LEG) to fabricate a wearable SAM-based UA patch sensor. This design provides superior UA detection performance compared to sensors based on conventional nanomaterials. In addition, we enhanced the detection accuracy and range by using an orthogonal approach that combines direct oxidation through differential pulse voltammetry (DPV) along with parallel biocatalytic amperometric detection. The resulting SAM-based UA orthogonal sensor patch demonstrated exceptional performance in wearable applications through tests measuring sweat UA levels in subjects before and after consuming a purine-rich diet. Graphical Abstract

Ding, Shichao↗
DOE OSTI2026

From MAST-U to STEP: Power exhaust control challenges and opportunities

This work explores the challenges and opportunities for power exhaust control in STEP, informed by dedicated MAST-U experiments. The STEP system primarily relies on hydrogenic and argon gas injection into the divertors, compensating for transients originating in the plasma core. Fast transients (>10 Hz) that evolve too quickly for actuators to compensate must be absorbed passively; the enhanced transient buffering of the foreseen long-legged divertor provides a clear advantage over conventional geometries, as demonstrated in the MAST-U Super-X divertor. Experiments further indicate that STEP’s tight divertor baffling enables near-independent control of the upper and lower divertors. The most challenging transients are expected from power-sharing fluctuations, as MAST-U experiments observed extremely fast dynamics. Fluctuations from core pellet fuelling remain relatively benign due to the small pellet size according to simulations. Exhaust control in a reactor like STEP requires an integrated approach befitting its machine-critical nature. A predictive control element, integrated with core plasma control, allows pre-emptive preparation of the divertor for incoming transients. An observer-based diagnostic approach is foreseen to monitor the divertor in the challenging reactor environment, supported by an extended diagnostic set in the non-nuclear phase to validate the required dynamic models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Wellbore injectivity response to step-rate CO 2 injection: Coupled thermo-poro-elastic analysis in a vertically heterogeneous formation

Safe and permanent carbon geological storages require an elaborate analysis of geomechanical stability. Subsurface injection of CO 2 changes the local temperature and pore pressure and, further, alters the stress due to thermo-poro-elastic responses. A permanent CO 2 storage testing was conducted in the water leg of Cranfield reservoir in Mississippi, USA, where hosted CO 2 enhanced-oil recovery activities. During CO 2 injection, the injection rate was ramped up twice but the bottom-hole pressure did not increase with the imposed injection rates as expected. This unexpected field observation suggests the possibility of an open-mode fracture development at the injector. However, the injector response and potential fracture development have not been rigorously interpreted with detailed near-wellbore temperature and pore pressure change upon the CO 2 injection. In this study, we performed history matching of CO 2 injection using coupled thermo-poro-elastic reservoir simulation to examine the possibility of fracturing. We built a reservoir model including vertical heterogeneity in both petrophysical and geomechanical properties estimated from well-logging analysis and laboratory experiments. The simulation results show that CO 2 injection changes stresses and support the hypothesis of development of an open-mode fracture at the injector during the Cranfield test. The near-injector region exhibits a large temperature reduction up to 55 °C with ensuing effective horizontal stress reduction up to 9.1 MPa. However, a caprock integrity issue is unlikely because of the horizontal stress contrast within layers and low hydraulic communication with the injection zone. This work indicates that the injectant temperature should be considered in the design of high-rate CO 2 injector.

58 GEOSCIENCES↗
DOE OSTI2021

Prediction of PbLi fluid flow and temperature field in a thermal convection loop for qualification of fusion materials

Two modeling tools, a thermohydraulics code and a computational model in COMSOL Multiphysics, have been developed, tested and then applied to the analysis of fluid flow and heat transfer in a thermal convection loop (TCL). Such a device has recently been used to experimentally evaluate corrosion compatibility of APMT (Fe–21Cr–5Al–3Mo) steel with high-temperature molten eutectic lead-lithium (PbLi) alloy at Oak Ridge National Lab, TN, USA. Here, the 1-D thermohydraulics code allows for rapid calculations of the loop parameters as a function of the applied heat flux. The supplemental COMSOL finite-element computations provide detailed 3-D velocity and temperature field data but are much more time consuming. Both modelling tools demonstrate an excellent agreement in the computed circulation velocity as well as maximum and minimum temperatures. The performed TCL analysis focuses on flow development in the “hot” and “cold” legs, formation of Dean vortices in corner regions, blocking effect of the immersed samples, and radiative and convective cooling effects under the experiment-relevant conditions for Prandtl number Pr = 0.015, Grashof numbers Gr ~10 7 , and Reynolds numbers Re ~10 4 .

36 MATERIALS SCIENCE↗
DOE OSTI2022

Route Optimization for Energy Efficient Airport Shuttle Operations - A Case Study from Dallas Fort Worth International Airport

Air travel and requisite surface traffic supporting passenger arrival/departure constitutes a significant portion of travel and emissions in cities with large airports. An airport trip can segment into three parts namely: i) travel from a location in the city to the airport; ii) travel from a parking lot or rental car center to the terminal (i.e., within the airport premises), and iii) travel inside the terminal. Depending on the airport access mode all or a part of these legs comprise a traveler’s journey to the airport. The priority of airport ground transport management teams is to provide passengers with a seamless travel experience within the airport, so it is understandable that within airport shuttle routes might not be optimized for minimizing energy consumption. Solutions that meet the dual objective of reducing energy consumption from airport shuttle operations without compromising on passenger travel experience are key to improving system efficiency. There is currently a dearth of research and tools that can inform airports in making such decisions. Addressing this need, this research effort puts forth an optimization model that generates optimal shuttle routes for a given set of constraints, and a discrete-event simulator that evaluates the optimal solutions in a stochastic environment to understand the tradeoffs between passenger wait times, and within airport shuttle energy consumption. The proposed set of tools are tested in the context of optimizing airport shuttles routes within the Dallas Fort Worth International Airport (DFW). In addition to shuttle spatial positioning, and passenger demand information, high-fidelity vehicle data was collected using data loggers installed on DFW shuttles. Results show that 20% energy reduction in shuttle operations is possible with a modest two-minute increase in average passenger wait times. The tools developed in this research effort are designed to be generalizable and can help optimize shuttle operations planning at any major airport.

air travel↗
DOE OSTI2022

Corrosion of 316H stainless steel in flowing FLiNaK salt

In this report type 316H stainless steel samples were exposed to flowing FLiNaK salt for 1000 h in a monometallic thermal convection loop (TCL) with a maximum temperature of 650 °C and a minimum of 540 °C. Samples in the hottest part of the TCL lost mass, with a maximum mass loss of 1.4 mg/cm 2 , while samples in the coldest parts of the TCL gained mass, with a maximum mass gain of 1.0 mg/cm 2 . Analysis of the samples that gained mass showed an Fe-rich layer on the sample surfaces, indicating that Fe, not Cr, was the primary deposition product in the TCL. Cr loss was apparent to a depth of ~5 µm in the hot leg. Post-exposure analysis of the salt showed major increases in the Cr, Fe, and Mn contents. The TCL was modeled using the TRANSFORM code. Modeled values matched the experimental temperature measurements showing that TRANSFORM is capable of accurately simulating the TCL conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

First snowflake divertor experiments in MAST-U tokamak

First snowflake (SF) divertor experiments in the MAST-U tokamak demonstrated steady-state snowflake-plus divertor configurations in 450 kA ohmic L-mode plasmas. The SF divertor configuration features a second poloidal field (PF) null in the divertor region close by or overlapping with the main X-point. The resulting low PF region and two additional divertor legs (strike points) may lead to additional power and particle flux sharing via a hypothesized convective cell, and increased plasma-wetted area and radiation. The free-boundary Grad–Shafranov equilibrium code FIESTA was used to design SF configurations with several inter-null distances and orientations. In the experiment, the SF configurations with inter-null distances 0.13–0.20 m and lasting 0.2–0.3 s were obtained. Parallel connection lengths between the midplane and the outer strike point in the SF configurations (evaluated at field lines 1–2 mm from the separatrix in the midplane) were 25–30 m, higher than in the standard divertor (20–25 m) or the Super-X divertor (25 m). Diagnostic measurements highlighted salient SF features. The infra-red video bolometer diagnostic showed that the radiated power peaking in the PF null region was not as pronounces as in the standard divertor. Divertor ion fluxes measured by target Langmuir probes showed increased ion flux in the plate region where a secondary SF strike point landed, concomitantly with the SF formation. These measurements may suggest that some particle and heat redistribution was taking place in the convective SF zone. The first SF experiments provide a basis for future SF studies in MAST-U tokamak with higher input power, improved plasma control and diagnostic measurements, to be compared with the modeling predictions of plasma convective SF mixing and lower density strike point detachment threshold.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Impact of nitrogen molecular breakup on divertor conditions in JET L-mode plasmas using SOLPS-ITER

SOLPS-ITER simulations of nitrogen-seeded, low-confinement mode plasmas in the Joint European Torus (JET) predict that the electron temperature in the low-field side (LFS) divertor leg is reduced locally by up to an order of magnitude when nitrogen is assumed to recycle as molecules (N 2 ) instead of atoms using a fixed nitrogen injection rate. The LFS divertor temperature reduction under the assumption of molecular recycling occurs due to a three-step mechanism: (1) the plasma penetration of nitrogen atoms is increased due to the strong triple bond of the N 2 molecule and the kinetic energy release in the dissociation event, both mechanisms contributing equally, (2) the abundance of (particularly multiply-charged) nitrogen ions in the divertor is increased and (3) the electron temperature is reduced due to the increase in radiation (by up to a factor of 4) from nitrogen ions. Setting the volume-integrated nitrogen radiated power to a constant value (0.6 MW) instead of the nitrogen injection rate, SOLPS-ITER predicts under the molecular nitrogen recycling assumption that the peak line-integrated N II, N III and N IV intensities in the LFS divertor are approximately within 15%, 35% and 5%, respectively, of the reference atomic nitrogen recycling case. The predicted peak N II, N III and N IV intensities under either assumption are within 30%, 65% and 5%, respectively, of measurements using the vertically viewing mirror-link divertor spectrometer (Meigs et al., 2010) in nitrogen-seeded JET L-mode plasmas (Lomanowski et al., 2019). ERO2.0 simulations using a constant nitrogen seeding rate on static background plasma solutions from EDGE2D-EIRENE (previously presented in Mäenpää et al., (2022), revised here to include fast reflections) predict that N II to N IV line emission is increased by 20% to 30% when nitrogen is assumed to recycle as molecules, demonstrating the importance of considering the effect of molecular dissociation reactions on the divertor plasma in a self-consistent manner.

Divertor↗
DOE OSTI2025

Balmer emission measurements in JET-ILW hydrogen, deuterium, tritium and deuterium-tritium low-confinement mode plasmas

Measurements of Balmer-alpha (B-α) and Balmer-gamma (B-γ), where B = H, D, or T isotopes of hydrogen, emission across the low-field side (LFS) divertor in JET ITER-like Wall (ILW), low-confinement mode (L-mode) plasma indicate that the divertor plasma was more strongly detached in deuterium, tritium and deuterium–tritium than in hydrogen plasmas. These measurements are consistent with the lower degree of detachment in hydrogen versus tritium plasmas inferred from Langmuir probes (Groth et al., 2023). The ratio of B-γ to B-α is a suitable indicator of high density/low temperature conditions because B-α emission is dominated by electron impact excitation with a small electron–ion recombination component regardless of electron temperature and density (for conditions in tokamak plasmas) whilst for B-γ the recombination component increases and the excitation component decreases as the electron temperature decreases and the electron density increases. Within the uncertainty of the measurements, the electron density at the low-field side separatrix and the power crossing the separatrix are similar to permit these comparisons. The B-©/B-α ratio is well correlated with the onset of detachment as measured by Langmuir probes (McCracken et al., 1998; Groth et al., 2023). The ratios of B-γ and B-α varied between 0.005 and 0.035 for low-recycling, high-recycling and partially detached conditions, and were 60–70 % higher in partially detached hydrogen than in tritium plasmas. In contrast, the difference between deuterium, tritium and 40–60 % deuterium–tritium is within 10 % and thus within the uncertainties of the measurements. Profiles of the B-α and B-γ emission was measured with two filtered CCDs connected to the visible lost light leg of JET’s mirror link spectroscopy system (Meigs et al., 2010; Lomanowski et al., 2014). Spatially (radial) narrower B-α profiles were measured with increasing isotope mass, while similarly broadened B-γ profiles were measured.

Balmer↗
DOE OSTI2023

Irradiation of ultrasonic sensors and adhesive couplants for application in light water reactor primary loop piping and components

The Electric Power Research Institute (EPRI) Nuclear Sector and US Department of Energy Light Water Reactor Sustainability Program are committed to engaging in research and development endeavors to address materials aging issues specific to long term operation of light water power reactors. To this effect, EPRI launched an industry initiative to develop nondestructive evaluation systems for online monitoring of existing cracks in light water reactor primary coolant loop piping and components. One of the goals of this initiative is to develop a sensor system (or systems) that can determine nondestructively if cracks are growing or arrested and, in the case of the former, to characterize their growth rates. A missing component of this initiative is an experimental assessment of how sensors and adhesive couplants will perform in service when exposed to chronic energetic neutron radiation, particularly at the primary coolant loop hot and cold leg dissimilar metal welds, which join the primary loop piping to the reactor pressure vessel and reside in the vicinity of the reactor core. The objective of this experimental study was to determine how ultrasonic transducers and adhesive couplants perform when exposed to irradiation in a test reactor to simulate and accelerate in-service exposure. Further, to achieve this objective, the signal stability of piezoelectric transducers and performance of adhesive couplants as a function of accumulated fast neutron fluence were characterized by collecting ultrasonic data in-situ during irradiation. Of particular interest were the ultrasonic signal quality and time decay of the amplitude of acoustic reflections as a function of fast neutron fluence. The results of the study showed that, of the 8 transducer/substrate sample assemblies tested, only 3 generated usable ultrasonic signals through the conclusion of the irradiation campaign. It was found that high temperature epoxy tends to ultrasonically couple the sensors to the substrates better than three types of refractory ceramic cements studied, as is supported by post irradiation examination. The results obtained through this experimental study will be utilized in the achievement of the overall goal of development of a sensor system to perform online monitoring of primary loop components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

3D probabilistic fracture mechanics / computational fluid dynamics simulation of a reactor pressure vessel under transient conditions

Reactor pressure vessels (RPVs) are safety-critical light-water-reactor components that, under irradiation, experience long-term material degradation in the form of embrittlement. This can increase their susceptibility to fracture under thermal-shock conditions, which could occur during off-normal transients such as loss-of-coolant accidents (LOCAs). During a LOCA, the most severe conditions for the RPV occur when emergency core cooling water is injected through the cold legs into the water-and-steam-filled RPV. The rapid cooling of the downcomer and internal RPV surface causes decreased temperature and elevated thermally driven tensile stresses in the RPV wall. This, combined with long-term material embrittlement, may cause fracture initiation at pre-existing flaws, challenging the integrity of the RPV. Assessing RPV integrity during transients with a large spatial variation in the coolant temperature requires a modeling approach that considers the effects of spatially varying coolant temperature on the fracture probability of a population of flaws distributed throughout the RPV, accounting for spatially varying embrittlement. Here, the present study addresses this need by demonstrating first-of-its-kind coupling of a high-fidelity 3D computational fluid dynamics code with 3D probabilistic fracture mechanics This was accomplished using representative models of a pressurized-water reactor subjected to small- and medium-break LOCA conditions, both of which can result in large spatial temperature variations. While the observed impact of accounting for 3D effects was minimal under the small-break LOCA this study indicates a significant increase in the probability of fracture initiation under the medium-break LOCA when 3D effects are considered, relative to a spatially uniform cooling scenario.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Performance evaluation of surface riding wave energy converter with linear electric generator

In this work, we devised a new WEC (wave energy converter) called SR-WEC (Surface Riding WEC). The SR-WEC consists of two bodies: the outer cylinder with an armature assembly (body #1) and a magnet assembly (body #2) sliding inside the armature. For the SR-WEC, the relative sliding displacement and velocity are caused by gravity acceleration and the outer cylinder's motions, and they lead to electrical power generation. To evaluate its performance, a numerical simulation tool was developed, which solves the fully-coupled floater-mooring-generator dynamics. During the developing stage, the appropriate hydrodynamics model, sliding mechanics model, mooring dynamics model, and LEG (linear electric generator) electro-magnetic model were independently developed and then fully coupled in time domain to account for the cross-coupling interactions among them. Then, the developed simulation tool was verified component by component against various laboratory tests. Subsequently, systematic parametric studies were conducted with several important design parameters under various wave conditions to enhance power generation. After that, the average output power was evaluated in enlarged operational wave conditions. The present SR-WEC is particularly designed to be efficient at low sea states, which is good since they cover the majority of typical annual sea states.

42 ENGINEERING↗
DOE OSTI2026

OC7 phase I: CFD investigation of viscous forces on rectangular members of semisubmersibles

In Phase I of the Offshore Code Comparison Collaboration 7 (OC7) project, we aim to address key questions related to the modeling of viscous hydrodynamic loads on floating platforms. Here, this paper presents results from a collaborative effort within Phase I of the OC7 project. We investigate viscous forces acting on the rectangular members of semisubmersible platforms using high-fidelity computational fluid dynamics (CFD) simulations. The parametric CFD analyses include two-and-a-half-dimensional (2.5D) simulations of pontoon sections of two different semisubmersible platform designs (the VolturnUS-S and the INO WINDMOOR) and full three-dimensional (3D) structure simulations of the VolturnUS-S platform. We extract both the added mass and drag coefficients that are typically used in engineering-level hydrodynamic models from the 2.5D forced oscillation simulations with various Keulegan-Carpenter numbers and compare them to the coefficients from the 3D forced oscillation simulations. We observe consistent variation of the coefficients along the pontoon legs due to 3D platform and free-surface effects. With the breadth of the simulations and component-level detailed analyses, this work establishes a useful database and several empirical formulas for selecting hydrodynamic coefficients when modeling semisubmersible platforms in engineering tools.

13 HYDRO ENERGY↗
DOE OSTI2020

Divertor heat flux challenge and mitigation in SPARC

Owing to its high magnetic field, high power, and compact size, the SPARC experiment will operate with divertor conditions at or above those expected in reactor-class tokamaks. Power exhaust at this scale remains one of the key challenges for practical fusion energy. Based on empirical scalings, the peak unmitigated divertor parallel heat flux is projected to be greater than 10 GW m -2 . This is nearly an order of magnitude higher than has been demonstrated to date. Furthermore, the divertor parallel Edge-Localized Mode (ELM) energy fluence projections (~11–34 MJ m -2 ) are comparable with those for ITER. However, the relatively short pulse length (~25 s pulse, with a ~10 s flat top) provides the opportunity to consider mitigation schemes unsuited to long-pulse devices including ITER and reactors. The baseline scenario for SPARC employs a ~1 Hz strike point sweep to spread the heat flux over a large divertor target surface area to keep tile surface temperatures within tolerable levels without the use of active divertor cooling systems. In addition, SPARC operation presents a unique opportunity to study divertor heat exhaust mitigation at reactor-level plasma densities and power fluxes. Not only will SPARC test the limits of current experimental scalings and serve for benchmarking theoretical models in reactor regimes, it is also being designed to enable the assessment of long-legged and X-point target advanced divertor magnetic configurations. Experimental results from SPARC will be crucial to reducing risk for a fusion pilot plant divertor design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Modeling Hydrogen Evolution Reaction Kinetics through Explicit Water–Metal Interfaces

Despite the apparent simplicity of the hydrogen evolution reaction (HER) and the decades of research into it, controversy remains in the literature regarding the identity of the active site and the competition between the Heyrovsky and Tafel steps. In this work, we use charge-extrapolated ab initio simulations with explicit water in conjunction with mean-field microkinetic modeling to explore the mechanism for HER on both close-packed (111) and stepped (211) transition metals. First, we show that atop H*, beyond a monolayer of hollow H*, is unlikely to play a role in the HER mechanism, given its very positive adsorption energies. The energetics suggests the Volmer–Heyrovsky mechanism to predominate on fcc transition metals under typical operating conditions. Here, we evaluate our theoretical results vs several experimental observations. We show that the Volmer–Heyrovsky mechanism predicts an activity volcano with its peak at a H* binding ΔG H* ≈ 0 eV, consistent with experiment. In contrast, the Volmer–Tafel volcano shows a broad rate plateau between ΔG H* ≈ 0 eV and ΔG H* ≈ – 0.4 eV. We find our theoretical Tafel slopes to be consistent with experimental ones on a range of transition metals. We show that, in line with experimental observations, the introduction of a CO(g) atmosphere shifts the strong binding metals toward the weak binding leg. Our study suggests that the simple thermodynamic approach to HER activity still holds, even when a detailed kinetic picture is considered.

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

Conformal High-Power-Density Half-Heusler Thermoelectric Modules: A Pathway toward Practical Power Generators

Thermoelectric generators (TEGs) exploiting the Seebeck effect provide a promising solution for waste heat recovery. Among the large number of thermoelectric (TE) materials, half-Heusler (hH) alloys are leading candidates for medium- to high-temperature power generation applications. However, the fundamental challenge in this field has been inhomogeneous material properties at large wafer diameters, insufficient power output from the modules, and rigid form factors of TE modules. This has restricted the transition of TEGs in practical applications for over three decades. Here, we successfully demonstrate large diameter wafers with uniform TE properties, high-power conformal hH TE modules for high-temperature application, and their direct integration on flue gas platforms, such as cylindrical tubes, to form large area flexible TEGs. This new conformal architecture design provides a breakthrough toward medium-/high-temperature TEGs over the conventional BiTe- and polymer-based flexible TEG design. In this work, a variable fill factor and greater flexibility due to the conformal design result in higher device performance as compared to conventional rigid TEG devices. Modules with 72-couple hH legs exhibit a device high-power-density of 3.13 W cm-2 and a total output power of 56.6 W under a temperature difference of 570 degrees C. These results provide a promising pathway toward widespread utilization of thermoelectric technology into the waste heat recovery application and will have a significant impact on the development of practical thermal to electrical converters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗