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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

R&D toward design for a pion-production target for Mu2e-II

The Mu2e experiment at Fermilab will search for evidence of charged lepton flavor violation by observing the conversion of a negative muon into an electron in the Coulomb field of a nucleus without emission of neutrinos and will probe effective new-physics mass scales in the 103-104 TeV range. One of the main parts of the Mu2e experimental setup is its target station in which negative pions are generated in interactions of the 8 GeV primary proton beam with a tungsten target, which will be capable of producing $2\times10^{17}$ negative muons per year. Mu2e can be extended by a next generation experiment, Mu2e-II, with a sensitivity improved by another factor of 10 or more as enabled by the PIP-II accelerator upgrade project. PIP-II is a 250-meter-long linac capable of accelerating a 2 mA proton beam to a kinetic energy of 800 MeV corresponding to 1.6 MW of power. To achieve another factor of ten improvement in sensitivity, Mu2e-II will require about 100 kW of proton beam on target, and the added power requires a new target design. We will present our progress in RD of a target station conceptual design for Mu2e-II, using the MARS15 and G4beamline Monte-Carlo codes toward a selection between granular, conveyor, and rotating cylindrical target options.

Lynch, Kevin Richard↗
DOE OSTI2022

Evaluation of Hopper Flow Prediction based on Cubical Triaxial Tester Data and FEM

A cubical triaxial tester (CTT) laboratory device was used to collect key bulk flow characteristics of Crumbles® 6mm rotary sheared woody biomass and Crumbles® 2mm rotary sheard corn stover. The flow properties and a CAD model of a hopper and conveyor system to predict the consistency of flow of material from the hopper. Prediction included the likeliness of jamming, bridging, or ratholing. Each material was then loaded into the hopper and the actual bulk flow was measured. Measured flow closely matched the predicted flow.

09 BIOMASS FUELS↗
DOE OSTI2022

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - Early Stage R&D: Phase 2 and FY21 (Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto substrates or membranes that are on moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final product. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes and electrolytes for energy storage, and barrier and membrane materials for decarbonization and air and water filtration. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and heated drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE↗
DOE OSTI2022

SMC Reinforced by Recycled or Textile Carbon Fiber

There is a significant need to expand material options for SMC that has traditionally used glass fibers for decades. There are several integral issues related to chopping and conveying a range of materials including glass, carbon, basalt, thermoplastic tapes, and recycled fibers. These are in a variety of forms including continuous tows, discontinuous agglomerates such as pyrolyzed carbon fibers that could be used to produce a range of SMC intermediates. Standard/conventional SMC processing is limited to cutting rotors specifically for glass and compounding with thermoset polyesters and some epoxies. The multi-material, multi-format line developed in this project is flexible to enable custom conveying and uses an interchangeable rotor dedicated for specific material types. The overall tasks undertaken in this project included: evaluation of the fiber feed mechanism, effect of textile grade carbon, evaluating servo motor controlling of conveyor, evaluate doctor box resin feed, evaluate compaction unit, evaluation of different formulations, and develop automation such as PLC programming. The new multi-material SMC line Version 2 (SCM-V2) incorporated servo motors over induction motors which gave the overall cutter system precision control and made it quiet. The addition of a 14-roll compaction unit at the end of the line in SMC-V2 enabled higher material wet out which was a limitation in the SMC Version 1 (SMC-V1). The cutters were further updated to reduce the cantilever overhang of the fiber which enabled more uniform cut lengths for glass, carbon, and basalt fibers. The overall instrumentation and system control including a remote control operation was enabled in the SMC-V2. The line speed is capable of 10-20 ft/minute. The cutting modules were designed and engineered for cutting glass, basalt and textile grade carbon in 300k and 450-600k format widths. The cutting trials were established for a range of fiber types. The study also demonstrated the utility of the line to cut and produce basalt fiber SMC. Initial trials were conducted on the properties from recycled carbon fiber (rCF) mats in epoxy resin. Overall, the Covid19 situation constrained the team from accessing the SMC line for over 18 months. Despite this challenge major advancements were made.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Altering Terahertz Sound Propagation in a Liquid upon Nanoparticle Immersion

One of the grand challenges of new generation Condensed Matter physicists is the development of novel devices enabling the control of sound propagation at terahertz frequency. Indeed, phonon excitations in this frequency window are the leading conveyor of heat transfer in insulators. Their manipulation is thus critical to implementing heat management based on the structural design. To explore the possibility of controlling the damping of sound waves, we used high spectral contrast Inelastic X-ray Scattering (IXS) to comparatively study terahertz acoustic damping in a dilute suspension of 50 nm nanospheres in glycerol and on pure glycerol. Bayesian inference-based modeling of measured spectra indicates that, at sufficiently large distances, the spectral contribution of collective modes in the glycerol suspension becomes barely detectable due to the enhanced damping, the weakening, and the slight softening of the dominant acoustic mode.

36 MATERIALS SCIENCE↗
NASA NTRS1971

Application of the GERTS II simulator in the industrial environment.

GERT was originally developed to aid in the analysis of stochastic networks. GERT can be used to graphically model and analyze complex systems. Recently a simulator model, GERTS II, has been developed to solve GERT Networks. The simulator language used in the development of this model was GASP II A. This paper discusses the possible application of GERTS II to model and analyze (1) assembly line operations, (2) project management networks, (3) conveyor systems and (4) inventory systems. Finally, an actual application dealing with a job shop loading problem is presented.

Whitehouse, G. E.↗
NASA NTRS1973

Apparatus and method for skin packaging articles

A system for skin packaging articles including a loading zone for positioning articles to be packaged upon a substrate, a thermoplastic film heating and vacuum operated skin packaging zone for covering the articles with film laminated to the substrate and a slitting zone for separating and trimming the individual skin packaged articles. The articles are passed to the successive zones. The loading zone may be adapted for conveyorized instead of hand loading. In some cases, where only transverse cutting of the film web is necessary, it may be desirable to eliminate the slitting zone and remove the skin packaged article or articles directly from the packaging zone. A conveniently located operating panel contains controls for effecting automatic, semiautomatic or manual operation of the entire system of any portions in any manner desired.

Madsen, B.↗
NASA NTRS1973

Sink-float ferrofluid separator applicable to full scale nonferrous scrap separation

Design and performance of a ferrofluid levitation separator for recovering nonferrous metals from shredded automobiles are reported. The scrap separator uses an electromagnet to generate a region of constant density within a pool of ferrofluid held between the magnetic poles; a saturated kerosene base ferrofluid as able to float all common industrial metals of interest. Conveyors move the scrap into the ferrofluid for separation according to density. Results of scrap mixture separation studies establish the technical feasibility of relatively pure aluminum alloy and zinc alloy fractions from shredded automobile scrap by this ferrofluid levitation process. Economic projections indicate profitable operation for shredders handling more than 300 cars per day.

Source record↗
NASA NTRS1977

Edge-following algorithm for tracking geological features

Sequential edge-tracking algorithm employs circular scanning to point permit effective real-time tracking of coastlines and rivers from earth resources satellites. Technique eliminates expensive high-resolution cameras. System might also be adaptable for application in monitoring automated assembly lines, inspecting conveyor belts, or analyzing thermographs, or x ray images.

Tietz, J. C.↗
NASA NTRS1977

Spectral structure of the field of solar radiation reflected from the ocean/atmosphere system

The statistical characteristics of the spectral structure of the brightness field of the ocean/atmosphere system are determined from the spectra of incident radiation and the radiation reflected from the ocean, obtained from aircraft (Conveyor 990) at heights of 0.3 and 10 km above the Atlantic Ocean. Analysis of the spectral structure reveals a weak correlation between atmospheric brightness variations in the 0.4 to 0.5 micron and 0.55 to 0.70 micron regions of the spectrum. This is attributed to the possible influence of variations of the scattering coefficient or optical thickness on the brightness variations (whose sign depends on the predominance of damping or multiple scattering in a given spectral region).

Malkevich, M. S.↗
NASA NTRS1977

Some opportunities in teleoperated mining

Processes involved in remote control mining (fragmentation, material handling, ground and environmental control) are discussed with reference to longwall shear mining, the method which affords the greatest potential for the use of teleoperated systems. The breakup and haulage procedures are outlined, with attention to environmental control subsystems, i.e., noise and dust abatement. A description of a four-legged chock, attached to a section of a face conveyor and operated remotely, is presented.

Palowitch, E. R.↗
NASA NTRS1979

Mining and beneficiation of lunar ores

The beneficiation of lunar plagioclase and ilmenite ores to feedstock grade permits a rapid growth of the space manufacturing economy by maximizing the production rate of metals and oxygen. A beneficiation scheme based on electrostatic and magnetic separation is preferred over conventional schemes, but such a scheme cannot be completely modeled because beneficiation processes are empirical and because some properties of lunar minerals have not been measured. To meet anticipated shipping and processing needs, the peak lunar mining rate will exceed 1000 tons/hr by the fifth year of operation. Such capabilities will be best obtained by automated mining vehicles and conveyor systems rather than trucks. It may be possible to extract about 40 kg of volatiles (60 percent H2O) by thermally processing the less than 20 micron ilmenite concentrate extracted from 130 tons of ilmenite ore. A thermodynamic analysis of an extraction process is presented.

Bunch, T. E.↗
NASA NTRS1978

High temperature thermal energy storage in moving sand

Several high-temperature (to 500 C) heat-storage systems using sand as the storage medium are described. The advantages of sand as a storage medium include low cost for sand, widespread availability, non-toxicity, non-degradation characteristics, easy containment, and safety. The systems considered include: stationary sand with closely spaced tubes throughout the volume, the use of a fluidized bed, use of conveyor belt transporter, and the use of a blower rapid transport system. For a stationary sand bed, very close spacing of heat transfer tubes throughout the volume is required, manifesting as high power related system cost. The suggestion of moving sand past or around pipes is intended to reduce the power related costs at the penalty of added system complexity. Preliminary system cost estimates are offered. These rough calculations indicate that mobile sand heat storage systems cost less than the stationary sand approach.

Turner, R. H.↗
NASA NTRS1979

An approach to automated longwall mining

The longwall system of mining coal, providing advantages in the areas of productivity as well as health and safety, is described, and technological developments leading to a full automation of the system are discussed. In the longwall system large blocks of coal (up to 600 feet wide and up to 5000 feet long) are developed, with each block mined out by taking successive slices across the short dimension of the block and loading the broken coal onto a conveyor. A self-advancing system supports the roof over the length of the face throughout cutting and loading, with the supports advanced with the face, and the roof allowed to collapse behind them. A double-ranging drum longwall shearer provides the system with an efficient yaw, roll, and variable-thickness vertical control. Currently two machine operators function as error detectors and controllers. It is shown that electronic sensors can lead to a fully automated vertical control system, and automatic roll control is achievable with available instruments and machine tilt actuators.

Palowitch, E. R.↗
NASA NTRS1982

Work Station For Inverting Solar Cells

Final work station along walking-beam conveyor of solar-array assembly line turns each pretabbed solar cell over, depositing it back-side-up onto landing pad, which centers cell without engaging collector surface. Solar cell arrives at inverting work station collector-side-up with two interconnect tabs attached to collector side. Cells are inverted so that second soldering operation takes place in plain view of operator. Inversion protects collector from damage when handled at later stages of assembly.

Feder, H.↗
NASA NTRS1982

Bonder for Solar-Cell Strings

String bonder for solar-cell arrays eliminates tedious manual assembly procedure that could damage cell face. Vacuum arm picks up face-down cell from cell-inverting work station and transfers it to string conveyor without changing cell orientation. Arm is activated by signal from microprocessor.

Garwood, G.↗