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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 OSTI2026

Rapid Electrochemical Carburization of Mild Steel

Next-generation iron production generates iron with 0 wt.% C, in contrast to contemporary blast furnace production of iron with 1 - 5 wt.% C. This makes new iron feedstocks difficult to use as a drop-in replacement in current steelmaking. We report results of an emissions-negative approach of carburizing iron or mild steel using molten salt electrochemistry and CO2. Electrochemical carburization of mild steel via molten carbonate salt electrolyte and CO2 bubbling shows rapid carbide development tunable by applied electric potential. Mild steel rods, serving as the cathode, show pearlite development at the surface after exposure to applied voltage in a LiKCO3 molten carbonate salt bath at 715 degrees C. The thickness of the pearlitic layer could be varied by changing the applied potential, with a strong difference in microstructure observed between an applied potential of -1.8 V and -2.4 V. This rapid carburization has multiple applications for enhancing steel production by upgrading the carbon content of low-carbon feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Regional analysis of aluminum and steel flows into the American automotive industry

Aluminum and steel represent the two most dominant metals in light duty vehicles, yet the flows of these materials into the American automotive industry have not been well characterized. This study proposes and implements a method for analyzing the flow of these metals into the automotive industry. We create a framework for performing regionally linked, sector specific material flow analyses and use this framework to trace flows of aluminum and steel entering the American automotive industry, focusing on flows downstream from raw material production. We show that automotive aluminum sheet and extrusions are sourced primarily from the NPCC (23%), SERC (20%), MRO (18%), and RFC (13%) NERC regions and a spatially unresolved Local region within the U.S. and Canada (18%). We determine that primary aluminum is largely from Canada (70%), nearly all from Quebec (69%). Further upstream, alumina and bauxite originate mostly from Brazil, Australia, and Jamaica. We also show that finished automotive steel is sourced primarily from the RFC (63%) and SERC (20%) regions. The crude steel supply similarly originates mainly from the RFC (69%) and SERC (7%) regions. Upstream raw materials including coke, coking coal, iron ore, lime, and steel scrap are primarily sourced from the U.S. with only direct reduced iron and pig iron used in electric arc furnace steel production coming mostly from outside the U.S. The framework developed here allows for increased spatial resolution of material flows, which can be used to develop more specific life cycle impact factors for life cycle assessments.

aluminum↗
NASA NTRS1972

Study of hot hardness characteristics of tool steels

Hardness measurements of tool steel materials in electric furnace at elevated temperatures and low oxygen environment are discussed. Development of equation to predict short term hardness as function of intial room temperature hardness of steel is reported. Types of steel involved in the process are identified.

Chevalier, J. L.↗
DOE OSTI2023

Directly monitoring the shift in corrosion mechanisms of a model FeCrNi alloy driven by electric potential

Abstract Stainless steels are used in a myriad of engineering applications, including construction, automobiles, and nuclear reactors. Developing accurate, predictive mechanistic models for corrosion and electrochemical corrosion kinetics of stainless steels has been a topic of research studies over many decades. Herein, we quantified the aqueous corrosion kinetics of a model austenitic Fe–18Cr–14Ni (wt%) alloy in the presence and absence of applied potential using systematic in situ electrochemical atomic force microscopy (EC-AFM) and transmission electron microscopy (TEM). Without an applied bias, vertical dissolution of corrosion pits is controlled by the surface kinetics/diffusion hybrid mechanism, whereas lateral dissolution is diffusion controlled. When an electric bias is applied, the increase in corrosion rate is dominated by the nucleation of new pits. These insights gained by the in situ EC-AFM will allow applications of this method for a quantitative understanding of corrosion of a wider class of materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cost and Life Cycle Analysis for Deep CO 2 Emissions Reduction for Steel Making: Direct Reduced Iron Technologies

Among heavy industrial sectors worldwide, the steel industry ranks first in carbon dioxide (CO 2 ) emissions. Technologies that produce direct reduced iron (DRI) enable the industry to reduce emissions or even approach net‐zero CO 2 emissions for steel production. Herein, comprehensive cradle‐to‐gate (CTG) life cycle analysis (LCA) and techno‐economic analysis (TEA) are used to evaluate the CO 2 emissions of three DRI technologies. Compared to the baseline of blast furnace and basic oxygen furnace (BF–BOF) technology for steel making, using natural gas (NG) to produce DRI has the potential to reduce CTG CO 2 emissions by 33%. When 83% or 100% renewable H 2 is used for DRI production, DRI technologies can potentially reduce CO 2 emissions by 57% and 67%, respectively, compared to baseline BF–BOF technology. However, the renewable H 2 application for DRI increases the levelized cost of steel (LCOS). When renewable natural gas (RNG) and clean electricity are used for steel production, the CTG CO 2 emissions of all the DRI technologies can potentially be reduced by more than 90% compared to the baseline BF–BOF technology, although the LCOS depends largely on the cost of RNG and clean electricity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Implications of an emission trading scheme for India’s net-zero strategy: a modelling-based assessment

To help meet its near-term NDC goals and long-term net-zero 2070 target, the Government of India has planned to establish a Carbon Credit Trading Scheme (CCTS), i.e. a domestic emission trading scheme (ETS). An ETS is an inherently cost-effective policy instrument for emission reduction, providing the greatest flexibility to reduce emissions from within and across sectors. An effective ETS requires design features that consider country-specific challenges and reflect its role within the larger policy package to achieve long-term emission reduction. Within the Indian context and in this study we therefore investigate—(i) what might be the role of the ETS in achieving India’s long-term mitigation targets? (ii) How might the various sectors interact under an emissions cap? (iii) How might the ETS interact with existing energy and climate policies? We do this analysis by running four main scenarios using the integrated assessment model GCAM (v6.0), adapted to India-specific assumptions and expectations. These scenarios are—(i) NZ (net-zero), (ii) NZ + ETS, (iii) NZ + CC (command and control), and (iv) NZ + RPO (renewables purchase obligations) + ETS. The NZ scenario assumes India’s near-term and long-term climate commitments of net zero by 2070. Scenarios with ETS (ii) and (iv) apply an emissions cap on four sectors—electricity, iron and steel, cement, and fertilizer. The scenario with CC applies a homogenous emission cap on each of the chosen sectors but does not allow cross-sectoral trading. The last scenario includes renewables purchase obligations (RPOs along with an ETS. We show that under a specific ETS emissions cap: (i) the electricity sector emerges as the largest source of cost-effective greenhouse gas (GHG) reduction options; (ii) ETS with trading across sectors is around 24% more cost-effective than ETS with trading only within sectors, (iii) RPOs can be complementary to an ETS although the impact of RPOs on GHG reductions in the electricity sector would need to be considered when setting the level of the ETS cap (or emissions intensity targets) or the RPO targets to avoid low carbon prices, and (iv) the direction and volume of financial transfers across sectors depends on allocation targets set by the government. Based on these results we provide design recommendations for India’s ETS.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1952

An Investigation Utilizing an Electrical Analogue of Cyclic Deicing of a Hollow Steel Propeller with an External Blade Shoe

A study has been made of the heat requirement for the cyclic de-icing of hollow steel propellers fitted with external blade heating shoes. Solutions to the equations for the heat flow in cyclic heating of propellers were obtained, using an electrical analogy. The study showed how the energy requirement for propeller de-icing with existing blade shoes could be decreased, and illustrated the effect of blade-shoe design on the energy requirement. It was demonstrated, for example, that by increasing the heating intensity and decreasing the heating period from those currently used the energy requirement could be decreased in the order of 60 percent. ' In addition, ft was shown that heating requirements could be decreased further, by as much as 60 percent, through proper design of the shoes. The' investigation also showed the energy requirement to increase with decreasing liquid-water content and air temperature. Uncertainties as to the exact values of convective heat-transfer coefficient prevailing over the surface of the blade and ice layer resulted in uncertainties of approximately proportional magnitude in the values of required heating intensity.

Neel, Carr B., Jr.↗
DOE OSTI2024

Carbon Capture from ArcelorMittal Hot Briquetted Iron Plant Using Air Liquide Cryocap™ FG Technology – FEED Study

The process of steel production is energy and carbon intensive with global average energy consumption of 5.5 MWh/tonne of steel and CO2 emission intensity of 1.83 tonne CO2/tonne of steel. The steel making process has inherent CO2 emissions from mineral conversion and is considered major contributors to the global carbon emissions. The steel industry is responsible for 8% of global carbon emissions. The main objective of this research project is to execute and complete a front-end engineering and design (FEED) study for a commercial-scale, carbon capture project that separates 95% of the total CO2 emissions at the ArcelorMittal’s Hot Briquetted Iron (HBI) plant in Portland, TX (Figure 1). The HBI is an ore-based metallic that is used as high-grade feedstock for high-quality steel via an Electric Arc Furnace (EAF) route. The HBI plant produces 2.0 million metric tonnes of high-quality HBI and emits approximately 1 million tonnes CO2/yr. The capture system is a Pressure Swing Adsorption (PSA) system assisted Cryocap™ FG technology (Figure 2). The captured CO2 will be pipeline grade and will be geologically stored in a facility within 10 miles of the CO2 source. The Host Site location in Corpus Christi, TX, is near hydrocarbon processing facilities and near Environmental Justice (EJ) and Qualified Opportunity Zone (QOZ) communities. Due to the location of the Host Site, the retrofit project offers the ability to demonstrate how a workforce focused on the fossil energy sector can be redirected to the clean- energy sector. The Air Liquide Cryocap™ capture technology is a proven technology and has been extensively examined for large industrial applications. It has been shown to be applicable to a variety of industrial applications including the steel industry. Cryocap™ FG (specific setup for Flue Gas application) consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The scope of this study incorporates completing FEED study of the CO2 capture system which includes point-source CO2 capture and balance-of-plant; Business Case Analysis (BCA) outlining the current and projected volumes of the steel plant’s point sources of CO2 and the potential utilization of tax credits, including its projected revenue and duration; Life Cycle Analysis (LCA); Environmental Justice Analysis; Economic Revitalization and Job Creation Outcomes Analysis; and Workforce Readiness Plan. The plant design work was divided into two components: Inside Battery Limits (ISBL) and Outside Battery Limits (OSBL). The ISBL focuses on the capture system, while the OSBL focuses on the utility feeds and ducting from the plant to the capture system. Various design and engineering deliverables will be developed to define commodity quantities, equipment specifications, and labour effort required to execute the project. These FEED study deliverables will be prepared with the intent to develop an overall project capital cost estimate consistent with an AACE Class 3 estimate. The modular approach for the Cryocap™ FG that is being designed for this study integrates compression, PSA, and cryogenic “bricks” to achieve the desired CO2 capture rates. This carbon capture system integrates easily with the existing plant, thus reducing project costs and risks. It is also capable of managing impurities such as nitrogen oxides (NOx), sulfur oxides (SOx), mercury, hydrocarbons, and particulate matter. The capture system has a smaller footprint than amine-based systems. The two-step process uses PSA to preconcentrate the CO2 in the feedstream and then uses the cryogenic portion to purify and compress the resulting high purity CO2 product. This combination of purification and compression (i.e., process intensification) significantly reduces the CAPEX associated with use of a separate compressor commonly utilized for amine solvent-based systems. Successful completion of the FEED study will provide DOE with a detailed understanding of the costs for scaling up this proven capture technology for commercial applications at industrial facilities.

42 ENGINEERING↗
NASA NTRS2013

Packaging Technologies for High Temperature Electronics and Sensors

This paper reviews ceramic substrates and thick-film metallization based packaging technologies in development for 500degC silicon carbide (SiC) electronics and sensors. Prototype high temperature ceramic chip-level packages and printed circuit boards (PCBs) based on ceramic substrates of aluminum oxide (Al2O3) and aluminum nitride (AlN) have been designed and fabricated. These ceramic substrate-based chiplevel packages with gold (Au) thick-film metallization have been electrically characterized at temperatures up to 550degC. A 96% alumina based edge connector for a PCB level subsystem interconnection has also been demonstrated recently. The 96% alumina packaging system composed of chip-level packages and PCBs has been tested with high temperature SiC devices at 500degC for over 10,000 hours. In addition to tests in a laboratory environment, a SiC JFET with a packaging system composed of a 96% alumina chip-level package and an alumina printed circuit board mounted on a data acquisition circuit board was launched as a part of the MISSE-7 suite to the International Space Station via a Shuttle mission. This packaged SiC transistor was successfully tested in orbit for eighteen months. A spark-plug type sensor package designed for high temperature SiC capacitive pressure sensors was developed. This sensor package combines the high temperature interconnection system with a commercial high temperature high pressure stainless steel seal gland (electrical feed-through). Test results of a packaged high temperature capacitive pressure sensor at 500degC are also discussed. In addition to the pressure sensor package, efforts for packaging high temperature SiC diode-based gas chemical sensors are in process.

Electronic packaging↗
NASA NTRS2013

Packaging Technologies for High Temperature Electronics and Sensors

This paper reviews ceramic substrates and thick-film metallization based packaging technologies in development for 500 C silicon carbide (SiC) electronics and sensors. Prototype high temperature ceramic chip-level packages and printed circuit boards (PCBs) based on ceramic substrates of aluminum oxide (Al2O3) and aluminum nitride (AlN) have been designed and fabricated. These ceramic substrate-based chip-level packages with gold (Au) thick-film metallization have been electrically characterized at temperatures up to 550 C. A 96% alumina based edge connector for a PCB level subsystem interconnection has also been demonstrated recently. The 96% alumina packaging system composed of chip-level packages and PCBs has been tested with high temperature SiC devices at 500 C for over 10,000 hours. In addition to tests in a laboratory environment, a SiC JFET with a packaging system composed of a 96% alumina chip-level package and an alumina printed circuit board mounted on a data acquisition circuit board was launched as a part of the MISSE-7 suite to the International Space Station via a Shuttle mission. This packaged SiC transistor was successfully tested in orbit for eighteen months. A spark-plug type sensor package designed for high temperature SiC capacitive pressure sensors was developed. This sensor package combines the high temperature interconnection system with a commercial high temperature high pressure stainless steel seal gland (electrical feed-through). Test results of a packaged high temperature capacitive pressure sensor at 500 C are also discussed. In addition to the pressure sensor package, efforts for packaging high temperature SiC diode-based gas chemical sensors are in process.

Chen, Liang-Yu↗
NASA NTRS1965

Coating method enables low-temperature brazing of stainless steel

Gold coated stainless steel tubes containing insulated electrical conductors are brazed at a low temperature to a copper coated stainless steel sealing block with a gold-copper eutectic. This produces an effective seal without using flux or damaging the electrical conductors.

Seaman, F. D.↗
NASA NTRS2004

EPS (Electric Particulate Suspension) Microgravity Technology Provides NASA with New Tools

The Electric Particulate Suspension is a fire safety ignition test system being developed at Iowa State University with NASA support for evaluating combustion properties of powders, powder-gas mixtures, and pure gases in microgravity and gravitational atmospheres (quenching distance, ignition energy, flammability limits). A separate application is the use of EPS technology to control heat transfer in vacuum and space environment enclosures. In combustion testing, ignitable powders (aluminum, magnesium) are introduced in the EPS test cell and ignited by spark, while the addition of inert particles act as quenching media. As a combustion research tool, the EPS method has potential as a benchmark design for quenching powder flames that would provide NASA with a new fire safety standard for powder ignition testing. The EPS method also supports combustion modeling by providing accurate measurement of flame-quenching distance as an important parameter in laminar flame theory since it is closely related to characteristic flame thickness and flame structure. In heat transfer applications, inert powder suspensions (copper, steel) driven by electric fields regulate heat flow between adjacent surfaces enclosures both in vacuum (or gas) and microgravity. This simple E-field control can be particularly useful in space environments where physical separation is a requirement between heat exchange surfaces.

Colver, Gerald M.↗
DOE OSTI2024

In-situ kinetic study of irradiation induced crystallization in amorphous Al 2 O 3

In the last ten years amorphous alumina coatings, deposited by Pulsed Laser Deposition, emerged as potential key enabling technology in the fields of heavy liquid metal fast reactors (lead and lead-bismuth) and fusion. In the former, as coating of the steel fuel cladding and in the latter as multifunctional coating providing a barrier against tritium permeation, steel corrosion and electrical insulation. Nevertheless, a detailed knowledge of the behavior of this thermodynamically metastable material at high temperatures and under neutron irradiation is still unknown. A knowledge gap that is mandatory to fill up for the deployment of this barrier technology. In the present work, we present a first step towards this goal, by the in-situ dynamic observation of the radiation induced crystallization processes of thin films of amorphous Al 2 O 3 , induced by ion-irradiation over an extensive range of temperatures (400-800 °C). The study was performed at the Intermediate Voltage Electron Microscope (IVEM)-Tandem Facility at Argonne National Laboratory. The experimental findings allow to elucidate the dependence of the grain growth on ion dose and temperature. A kinetic approach has been used to derive the process activation energies and other important parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Dynamic Life Cycle Assessment for Evaluating the Global Warming Potential of Geothermal Energy Production Using Inactive Oil and Gas Wells for District Heating in Tuttle, Oklahoma

Repurposing abandoned oil and gas infrastructure for geothermal energy production has great potential to reduce greenhouse gas (GHG) emissions. This study quantified the life cycle global warming potential of geothermal energy production using four inactive oil and gas wells repurposed for district heating in Tuttle, Oklahoma. A cradle-to-grave prospective life cycle assessment was performed to compare GHG emissions between the geothermal district heating system and conventional natural gas-fired heating system from 2020 to 2050. For initial implementation of the geothermal system, we investigated two approaches: 1) repurposing abandoned infrastructure from a nearby oil and gas well site, and 2) production and injection well drillings including new construction of a central heat exchange station. Environmental impacts from the geothermal system were estimated for five scenarios where a natural gas peaking boiler is incorporated to supply peak heat demand. The prospective results indicated that cumulative reduction in GHG emissions from transitioning to the geothermal district heating system increase over time as a function of future renewable resource penetration and technological advancements within electricity, fuel, and steel production. Over 30 years, the global warming potential associated with the district heating demand will have been reduced by up to 24 % with the repurposed system. These results imply that repurposing existing oil and gas infrastructure for geothermal energy systems of district heating will bring future climate benefits.

abandoned oil and gas wells↗
DOE OSTI2024

H2Integrate [SWR-23-31]

H2Integrate(H2I) is an open-source Python package for hybrid systems engineering design and technoeconomic analysis. It models and optimizes hybrid energy plants that produce electricity, hydrogen, ammonia, steel, and other products. H2Integrate is designed to be flexible and extensible, allowing users to create their own components and models for various energy systems. The tool currently includes distributed energy generation (wind, solar, wave, tidal), battery storage, hydrogen, ammonia, methanol, and steel technologies. Other elements such as desalination systems, pipelines, compressors, and storage systems can also be included as developed by users. Some modeling capabilities in H2Integrate are provided by integrating existing tools, such as HOPP, PySAM, ORBIT, and ProFAST. The H2Integrate tool is built on top of NASA's OpenMDAO framework, which provides a powerful and flexible environment for modeling and optimization.

King, Jennifer [National Renewable Energy Laborato↗
NASA NTRS1977

Corrosion inhibitors for solar heating and cooling systems

Problems dealing with corrosion and corrosion protection of solar heating and cooling systems are discussed. A test program was conducted to find suitable and effective corrosion inhibitors for systems employing either water or antifreeze solutions for heat transfer and storage. Aluminum-mild-steel-copper-stainless steel assemblies in electrical contact were used to simulate a multimetallic system which is the type most likely to be employed. Several inhibitors show promise for this application.

Humphries, T. S.↗