SEARCH · Search NASA

Results for “Complex industrial process”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 667 records · Page 37

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Down-selection of Innovative Fusion Materials

The goal of this proposal is to develop and fundamentally understand the microstructure of refractory multi-component alloys (MCA) as fusion-relevant plasma facing and structural materials, a step to down-select innovative fusion materials prior to the process of advancing their technology readiness level (TRL). Developing materials is paramount to enable fusion as energy source since no existing material is capable of coping with such extreme conditions. We will aim at understanding the role of chemistry and microstructure in these complex multi-component alloys systematically comparing their performance with pure tungsten materials in terms of mechanical properties and manufacturability. Such understanding will open opportunities to optimize MCAs for fusion applications and has a potential of attracting industry partnership.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Putting the 'super' in supercomputers

Computers used for numerical simulations of physical phenomena, e.g., flowfields, meteorology, structural analysis, etc., replace physical experiments that are too expensive or impossible to perform. The problems considered continually become increasingly more complex and thus demand faster processing times to do all necessary computations. The effects components technologies have on computer speed are leveling off, leaving new architectures and programming as the only currently viable means to upgrade speed. Parallel computations, either in the form of array processors, assembly line processing or multiprocessors are being explored using existing microprocessor technologies. Slower hardware configurations can also be made equivalent to faster supercomputers by economic programming. The availability of rudimentary parallel architecture supercomputers for general industrial use is increasing. Scientific applications continue to drive the development of more sophisticated parallel machines.

Schulbach, C.↗

NASA NTRSDate not supplied

Probabilistic Approach to Assessing Capture System Performance Margin in Mars Sample Return's Capture, Containment, and Return System

In the aerospace industry, there are standard design principles and/or rule-of-thumb targets that define healthy levels of margins required at each developmental milestone for traditional metrics, such as mass, thermal, and power margins. When the technical resource is “non-traditional,” in the sense that guiding margin principles are non-existent, systems engineering processes are required to internally generate performance targets and methodologies to assess the system against the derived targets. This paper presents a probabilistic approach for assessing complex time-critical operations which applies global sensitivity analyses to identify input parameters that should drive the design. This approach is used to design a critical payload required for the Mars Sample Return campaign aiming at bringing back rock and atmospheric samples from Mars.

Performance Margins↗

DOE OSTI2014

Clean Energy Manufacturing: U.S. Competitiveness and State Policy Strategies (Presentation)

The capital intensive nature of clean energy technologies suggests that manufacturing clean energy equipment has the potential to support state and local economic development efforts. However, manufacturing siting decisions tend to be complex and multi-variable decision processes that require in-depth knowledge of specific markets, the logistical requirements of a given technology, and insight into global clean tech trends. This presentation highlights the potential of manufacturing in supporting economic development opportunities while also providing examples of the financial considerations affecting manufacturing facility siting decisions for wind turbine blades and solar PV. The presentation also includes discussion of other more qualitative drivers of facility siting decisions as gleaned from NREL industry interviews and discusses strategies state and local policymakers may employee to bolster their chances of successfully attracting clean energy manufacturers to their localities.

14 SOLAR ENERGY↗

NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗

DOE OSTI2020

Flammable Gas Generation and Control at the Idaho Completion Project Legacy Combustible Gas Generation - 20191

On April 11, 2018, four drums containing transuranic waste at the Idaho National Laboratory underwent over-pressurization, ejecting their lids and spreading radiological waste within a facility. An investigation has found that waste in the drums generated methane gas, which contributed to the event. Subsequent to the investigation, the potential for drums to have methane and other flammable analytes whose concentrations could approach or exceed the lower flammability limit (LFL) and the adequacy of the controls to prevent or mitigate a possible deflagration was evaluated. An extensive review of the historical records was performed to determine how many drums exceed the LFL. The historical record identified a small quantity of drums that exceeded the LFL for xylene, hydrogen, and methane. The primary codified applicable code or standard for handling drums is 29 CFR 1910.120 (j) 'Handling Drums and Containers.' It is used throughout the commercial and government sector. This code is integrated throughout the Fluor Idaho safety management programs and procedures to control the Standard Industrial Hazards (SIHs) associated with drum and container handling. Example requirements include: - Drums and containers are inspected, and their integrity assured prior to being moved. - Site operations are organized to minimize the amount of drum or container movement. - When there is a reasonable possibility of flammable atmospheres being present, material handling equipment and hand tools are of the type to prevent sources of ignition. Drums and containers under pressure, as evidenced by bulging or swelling, are not moved until the cause for excess pressure is determined and appropriate containment procedures have been implemented to protect employees from explosive relief of the drum. Drums which exceed the WIPP FGA limit have NCRs associated with them. Once a drum fails flammable gas sampling, an NCR is initiated. The NCR drives placement into NCR dense pack rows. A standing order drives placement of the FGA failures to a single planer segregation location. These drums are not allowed for further processing or shipment until the NCR has been cleared. Once in the single planer rows, follow-up FGA testing is performed by CCP. The NCR is dispositioned by follow-up sampling occurring after adequate time has been provided for the gas to diffuse through the filter assembly, or, in some cases, the drums are repackaged into additional drums to reduce the source term. To date, the ICP project has performed approximately 1.5 million drums moves without a deflagration event due to combustible gas generation. Flammable gas generation in a transuranic waste drum is not unique to the ICP but is common across the DOE complex. Based on the experience at Idaho, application of industry standards is sufficient to control the risk of drum deflagration due to drum movements. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Direct ink writing of aqueous-based Gadolinium (III) oxide slurries

Gadolinium (III) oxide (gadolinia, Gd 2 O 3 ) has recently been identified as an intriguing material for applications in the medical, solid oxide fuel cell, and nuclear industries. This interest drives the need for developing and understanding manufacturing techniques that can produce dense Gd 2 O 3 structures. Direct ink writing (DIW), an extrusion-based additive manufacturing method, has also garnered interest because of its capability to produce dense ceramic parts with increased complexity in an economical manner. In this study, DIW was explored as a manufacturing technique for Gd 2 O 3 . Experiments were performed to develop Gd 2 O 3 bearing inks capable of being processed via DIW. Ink solids loading and sintering temperatures were varied to assess their impact on the final density and microstructure. Optimum sintering conditions are proposed and were experimentally verified at a dwell temperature of 1500°C. Gd 2 O 3 samples were successfully manufactured using DIW, achieving densities greater than 96 % of the theoretical density.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Utilizing a Dynamic Segmentation Convolutional Neural Network for Microstructure Analysis of Additively Manufactured Superalloy 718

Additive manufacturing (AM) is revolutionizing almost all industries through the production of intricate geometries previously prohibited by cost or machinability. Ni-based superalloys form a primary alloy class for high temperature applications in the petrochemical, aerospace, and nuclear industries because of their intrinsic resistance to creep and the ability to heat treat the superalloy for high strength. Despite these attractive properties, the extreme work hardening of Ni-based superalloys makes traditional manufacturing of complex shapes difficult and thus, these alloys are an attractive target for AM. Superalloy 718 was chosen as an example superalloy because of the wide variety of precipitates that can form within its composition space from the repetitive heating and cooling cycles of the AM process. The precipitates and other microstructure features, such as grain boundaries and dislocations, will dictate the mechanical properties and thus, there is an extensive challenge to characterize the size, number density, composition, and volume fraction of each microstructural feature from AM fabrication using analytical electron microscopy. This work focused on the application of a pixel-wise classification machine learning (ML) model called a dynamic segmentation convolutional neural network (DSCNN) to identify the microstructural features of an as-fabricated additively manufactured superalloy 718.

Taller, Stephen↗

DOE OSTI2025

Metal additive manufacturing simulation across length, time, and computing scales

Metal additive manufacturing (AM) offers a unique opportunity for production of advanced materials and complex geometries. However, variability in microstructure and properties challenges conventional approaches to design, process optimization, qualification, and materials selection. Modeling and simulation can improve understanding of AM processing and materials, but also poses major challenges for existing computational methods. Simultaneously, modern scientific computing hardware has become increasingly complex, most notably with the adoption of hybrid architectures such as Graphical Processing Units (GPUs). If appropriately utilized, emerging computational capabilities provide an opportunity to reveal new insight into AM processing and the resulting material structure and properties. In this review we describe the computational AM landscape, identify critical gaps, and highlight opportunities to impact the development and application of AM. First, the requirements and challenges of representative AM problem statements will be defined. Here, these problems range from scientific studies to industrial applications and are designed to capture the breadth of challenges facing the AM community. Next, the current state of AM modeling and simulation is evaluated, broken down by enabling hardware and software, process simulation, microstructure simulation, and property simulation. Each section describes the diversity of simulation approaches and associated trade-offs in physical fidelity and computational expense. Each area is then assessed based on their suitability and readiness for current and developing computational architectures. Lastly, the greatest opportunities for future research and application are highlighted, including gaps in modeling capabilities, opportunities for near-term application, and key scientific challenges.

additive manufacturing↗

NASA NTRSDate not supplied

Crew Performance Support System to Aid in Anomaly Resolution: Concept of Operations

As missions progress into deep space, communication delays and disruptions will disenable the crew’s reliance on Earth experts. There are also limitations in the amount of data that can be downlinked to the ground. It is prudent to assume that critical, complex vehicle or habitat sub-systems will malfunction at a time when a lunar or Mars’ crew cannot rely on the Earth-Support team to detect, diagnose and resolve the problem and it is impractical to expect a small crew to step-in with the same level of expertise as 50+ authorities. The crew will need novel processes and advanced technological support to independently identify and resolve safety- and time-critical anomalies. That a self-reliant crew is unable to respond appropriately to time-critical anomalies is a significant risk to crew safety and mission success. This risk is driven by several factors; novel and unanticipated anomalies would not have been trained pre-flight, the crew could forget their pre-flight training or spaceflight stressors could impair the crew’s problem-solving ability. At last year’s IWS, Beard reported that a single spaceflight stressor (elevated CO2) could undermine the crew’s ability to independently respond to emergencies. Concept of Operations (ConOps) provide a common view of future system functions to all stakeholders. For the current project, a ConOps was developed that describes the operational processes, practices and capabilities needed by a crew of astronauts on deep space missions to autonomously respond to anticipated and unanticipated anomalies. It is crucial to recognize that, as of August 2018 existing technologies are unable to effectively support crew anomaly response to unanticipated events. “Intelligent technology” has not reached a maturity level that permits generalizing a solution to novel situations. For example, to train intelligent technology requires volumes of data that do not exist. The complexities involved in a manned mission to Mars cannot be compared to sending rovers to Mars using scripted software. This ConOps proposes a Crew Performance Support System (CPSS) that will push NASA and its industry partners toward what will be required for a safe and successful manned mission to Mars. Anomaly resolution during a deep space mission will take place within a dynamic, or changing, context. The figure to the left shows five broad contextual variables: the organizational culture, mission context, system characteristics, team characteristics and individual characteristics. The yellow arrow indicates that spaceflight and task-related stressors can affect system, team and individual crewmember characteristics and therefore anomaly response potential. The figure depicts a protective umbrella of Human-System Integration (HSI) principles that should be instituted during CPSS development including a balanced workload, shared situation awareness and building an appropriate level of trust in the automation. The figure also depicts two interrelated and cooperative components, an HSI Data System and other Enabling Capabilities will be required to support crew anomaly response and Earth-Support situation awareness. As we journey from ISS to Gateway to Mars, multiple, simultaneous and integrated research and development efforts (i.e., support systems co-evolution) must be implemented to meet the problem-solving challenges a self-reliant crew will face on a Mars’ mission. The crossovers between the capabilities are just as important as the discrete capabilities themselves. As the capabilities mature, the lines between the support subdomains will blur and an integrated system will emerge. The ConOps summarizes current knowledge about how highly trained people solve anomalies in safety- and time-critical situations, describes a group of capabilities that could help to reduce the extant risk and documents requirements levied on additional systems that provides critical inputs to the CPSS. Scenarios are used to promote a shared understanding of processes, practices and technological goals needed for safe and productive manned missions beyond LEO.

HSIA risk↗

DOE OSTI2019

Environmental Assessment for Use of DOE-Owned High-Assay Low-Enriched Uranium Stored at Idaho National Laboratory

The U.S. Department of Energy (DOE) proposes to make available about 10 Metric Tons (MT) of High-Assay Low-Enriched Uranium (HALEU ) feedstock produced through the electrometallurgical treatment (EMT) process, and other small quantities of HALEU stored at Idaho National Laboratory (INL) for research development & demonstration in support of the commercial nuclear industry and government agencies, including use in advanced reactors. HALEU is a term applied to uranium that is enriched in the uranium-235 (U-235) isotope to a value that is 5% to 20% of the total uranium. Private sector advanced nuclear reactor designs and advanced nuclear fuel designs call for use of HALEU, but currently no commercial facility manufactures HALEU. DOE proposes to expand the fuel fabrication capability at INL to produce HALEU fuel at INL from 10 MT of HALEU feedstock to meet near-term needs. The production requires expansion of the fuel fabrication capability, including the purchase of new equipment and use of facilities at INL’s Materials and Fuels Complex (MFC) and the Idaho Nuclear Technology and Engineering Center (INTEC). DOE has made no decision on the specific use of the fuel. The fuel could be used in advanced reactor design or for the purpose of research and development. DOE would work with other Federal agencies and commercial vendors to determine use of HALEU fuel. Use of this HALEU, including its potential use in a future nuclear reactor, will be analyzed in future National Environmental Policy Act (NEPA) documents by the appropriate agency. The EMT process in operation at the INL converts sodium-bonded spent nuclear fuel into waste forms suitable for disposal as high-level waste and a HALEU product that is unsuitable for diversion to nuclear weapons but could be either reused in fuel or disposed of as waste. The Final Environmental Impact Statement for the Treatment and Management of Sodium-Bonded Spent Nuclear Fuel, DOE/EIS-0306, DOE 2000) discussed the EMT process, but did not make a decision on the disposition or use of the HALEU product from the EMT process. This Environmental Assessment (EA) addresses the HALEU product as HALEU feedstock in production of HALEU fuel.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2019

An Integrated Risk Assessment Process for Digital Instrumentation and Control Upgrades of Nuclear Power Plants

Most of the existing nuclear power plants (NPPs) in the world rely on traditional analog instrumentation and control (I&C) systems for monitoring, control, and protection functions. With the industrial base largely moving to digital systems, the operation and maintenance of plants involves managing issues including lack of needed analog spare parts, increasing maintenance costs, and the loss of vendor support. Compared with existing analog I&C systems, digital I&C systems have significant functional advantages, such as reliable system performance in terms of accuracy and computational capability, high data handling and storage capabilities to fully measure and display operating conditions, and improved capabilities (e.g., fault tolerance, self-testing, signal validation, process system diagnostics). Therefore, the U.S. nuclear power industry has initiated the replacement of existing, aging analog systems with digital I&C technology, and is developing new designs for advanced plants using digital systems in integrated control rooms to provide modern control and protection systems. However, the qualification of digital I&C systems remains a challenge, especially the issue of software common cause failure (CCF), which has been difficult to address. A CCF is the malfunction of two or more plant components or functions due to a single failure source. CCFs have the potential to generate unanalyzed events or sequences that may not be bounded by previous plant accident analyses, therefore, to challenge the plant safety. Existing analyses on CCF in I&C systems are mainly focusing on hardware failures. With the application and upgrades of new digital I&C systems, software CCFs due to design flaws have become a potential threat to plant safety considering most redundancy designs are using the similar digital platforms or software in the operating and application systems. With complex multi-layer redundancy designs to meet the single failure criterion, these I&C safety systems are of a particular concern in the U.S. Nuclear Regulatory Commission (NRC) licensing procedures. Therefore, there is a need to develop an integrated risk assessment strategy with digital CCF and plant transient responses considered to assure the long-term safety and reliability of vital digital systems and reduce uncertainties in costs, time, and support integration of digital systems in the plant. The overall goal of this project is to deliver a strong technical basis to support effective, licensable, and secure digital I&C technologies for the digital upgrades to existing NPPs. To deal with the expensive licensing justifications from regulatory insights, this technical basis is instructive for nuclear vendors and utilities to effectively lower the costs associated with digital compliance and speed-up industry advances by: (1) defining an integrated risk-informed analysis process for digital I&C upgrades including hazard analysis, reliability analysis, and consequence analysis; (2) applying systematic and risk-informed tools to address CCFs and quantify responding failure probabilities for digital I&C technologies; (3) evaluating the impact of digital failures at the individual level, system level, and plant level; and (4) providing insights and suggestions on designs to manage the risks, thus to support the development, licensing, and deployment of advanced digital I&C technologies on NPPs. Upgrading digital I&C (safety and non-safety related) systems in existing NPPs within a cost-effective and regulatory acceptable way offers the foremost means of performance improvements and cost-reductions for existing NPPs. One key outcome of this project is to perform plant-specific risk assessment to provide a sustainable scientific support for enabling industry to balance the digital-related risks, costs, reliability, and safety.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Bridging microscopic dynamics and rheology in the yielding of charged colloidal suspensions

The yielding of soft materials is critical to many natural and industrial processes, yet experimental insights into microscopic aspects of yielding are limited. This study combines angle X-ray scattering, X-ray photon correlation spectroscopy, and in situ rheology (Rheo-SAXS-XPCS) with fast lubrication dynamics simulations to examine how interparticle interactions influence yielding in charged colloidal suspensions. By tuning attraction through salt addition, we compare repulsive and attractive systems under deformation. Repulsive suspensions yield uniformly with Andrade-like creep and minimal structural change. In contrast, attractive suspensions show complex behaviors, including shear banding, delayed yielding, and resolidification, governed by transient dynamics at shear band interfaces. These results directly link microscopic particle dynamics to macroscopic flow and demonstrate how interaction potentials control rheological behavior. This work offers a framework for designing soft materials with tailored properties for applications in coatings, food processing, drug delivery, and other technologies requiring precise mechanical control.

Molecular Dynamics Simulation↗

DOE OSTI2023

Determining mating type and ploidy in Rhodotorula toruloides and its effect on growth on sugars from lignocellulosic biomass

Rhodotorula toruloides is being developed for the use in industrial biotechnology processes because of its favorable physiology. This includes its ability to produce and store large amounts of lipids in the form of intracellular lipid bodies. Nineteen strains were characterized for mating type, ploidy, robustness for growth, and accumulation of lipids on inhibitory switchgrass hydrolysate (SGH). Mating type was determined using a novel polymerase chain reaction (PCR)-based assay, which was validated using the classical microscopic test. Three of the strains were heterozygous for mating type (A1/A2). Ploidy analysis revealed a complex pattern. Two strains were triploid, eight haploid, and eight either diploid or aneuploid. Two of the A1/A2 strains were compared to their parents for growth on 75%v/v concentrated SGH. The A1/A2 strains were much more robust than the parental strains, which either did not grow or had extended lag times. The entire set was evaluated in 60%v/v SGH batch cultures for growth kinetics and biomass and lipid production. Lipid titers were 2.33–9.40 g/L with a median of 6.12 g/L, excluding the two strains that did not grow. Lipid yields were 0.032–0.131 (g/g) and lipid contents were 13.5–53.7% (g/g). Four strains had significantly higher lipid yields and contents. Finally, one of these strains, which had among the highest lipid yield in this study (0.131 ± 0.007 g/g), has not been previously described in the literature.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Data for Determining Mating Type and Ploidy in Rhodotorula toruloides and its Effect on Growth on Sugars from Lignocellulosic Biomass

Rhodotorula toruloides is being developed for the use in industrial biotechnology processes because of its favorable physiology. This includes its ability to produce and store large amounts of lipids in the form of intracellular lipid bodies. Nineteen strains were characterized for mating type, ploidy, robustness for growth, and accumulation of lipids on inhibitory switchgrass hydrolysate (SGH). Mating type was determined using a novel polymerase chain reaction (PCR)-based assay, which was validated using the classical microscopic test. Three of the strains were heterozygous for mating type (A1/A2). Ploidy analysis revealed a complex pattern. Two strains were triploid, eight haploid, and eight either diploid or aneuploid. Two of the A1/A2 strains were compared to their parents for growth on 75%v/v concentrated SGH. The A1/A2 strains were much more robust than the parental strains, which either did not grow or had extended lag times. The entire set was evaluated in 60%v/v SGH batch cultures for growth kinetics and biomass and lipid production. Lipid titers were 2.33–9.40 g/L with a median of 6.12 g/L, excluding the two strains that did not grow. Lipid yields were 0.032–0.131 (g/g) and lipid contents were 13.5–53.7% (g/g). Four strains had significantly higher lipid yields and contents. One of these strains, which had among the highest lipid yield in this study (0.131 ± 0.007 g/g), has not been previously described in the literature.

Conversion↗

DOE OSTI2015

CMM Interim Check Design of Experiments (U)

Coordinate Measuring Machines (CMM) are widely used in industry, throughout the Nuclear Weapons Complex and at Los Alamos National Laboratory (LANL) to verify part conformance to design definition. Calibration cycles for CMMs at LANL are predominantly one year in length and include a weekly interim check to reduce risk. The CMM interim check makes use of Renishaw’s Machine Checking Gauge which is an off-the-shelf product simulates a large sphere within a CMM’s measurement volume and allows for error estimation. As verification on the interim check process a design of experiments investigation was proposed to test a couple of key factors (location and inspector). The results from the two-factor factorial experiment proved that location influenced results more than the inspector or interaction.

42 ENGINEERING↗

DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRSDate not supplied

Femtosecond Laser-Structured Transparent Anti-Fog Polycarbonate for Visor Applications

AlchLight has developed transparent anti-fog superhydrophobic polycarbonates for spacesuit helmets using femtosecond pulsed laser surface patterning technology. In contrast to conventional complex chemical coating processes, our laser patterning permanently alters the intrinsic wetting property of polycarbonate with little change to its transparency. The processing procedure is studied and optimized to produce the ideal superhydrophobic property and transparency. We were able to obtain a high contact angle (>150°), small sliding angle (<10°), and high transmission (>70%) over the visible wavelengths for polycarbonates. The anti-fog effect was also investigated. This technology will have a range of applications in spacesuit, automotive, medical, energy, and sports industries.

Spacesuit↗