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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

Use of friction stir processing to synthesize nanocrystalline, grain boundary segregating Fe-Ti alloys

Grain boundary segregating alloys, a class of alloys designed such that nanocrystalline grain sizes are thermodynamically stabilized by the presence of high segregation energy solutes at the grain boundaries, are typically produced through geometrically limited processing techniques such as equal channel angular extrusion or thin film sputtering. Here, this study explores the use of friction stir processing (FSP) as a novel means of studying and producing these alloys using a test system of Fe-6at%Ti. Spot FSPs with a range of processing parameter sets were produced on bulk, coarse grained bars of material and optimal parameters were identified. Microscopy identified a range of processed materials which achieved nanocrystalline grains on the order of 100 nm, delineating a critical window of processing parameters which limit heat input while inducing sufficient plastic deformation for grain refinement. The finest grained nanocrystalline Fe-Ti achieved a hardness of 7.68 GPa, a significant increase in hardness over pure Fe with a similar microstructure due to increased dislocation density from FSP as well as several strengthening mechanisms produced through the presence and segregation of Ti. These results demonstrated the feasibility of using FSP to produce nanocrystalline grain boundary segregating alloys.

Fe alloys↗

Friction surfacing and cold spray deposition for surface crack repair in austenitic stainless steels

Two technologies, friction surfacing (FS) and cold spray deposition (CSD), have been investigated for field repair of cracks in 304L austenitic stainless steel. Both technologies are low-heat-input, solid-state technologies that do not introduce the detrimental effects of solidification, such as compositionally segregated microstructures and shrinkage stresses. Friction surfacing was performed using a 304L stainless steel rod over the substrate of the same material. Further, the process was performed at a high spindle speed of 20,000 RPM allowing for process forces below 500N to be used effectively. Spherical gas-atomized 304L stainless steel powder, in size range of 25–44 µm, was used as feedstock powder for the cold spray process for deposition on 304L substrates. Both technologies showed leak-tight crack repair capabilities on ~30–50 µm wide simulated through-crack specimens based on helium leak tests.

36 MATERIALS SCIENCE↗

Force reduction of friction stir welding and processing of steel

Friction stir welding and processing (FSW&P) is considered as a new fabrication method for canisters and repair of existing dry cask storage system canisters (generally made of austenitic stainless steel). Low heat input compared to fusion joining processes and grain refinement associated with low-temperature FSW&P result in a material with improved mechanical properties and equivalent generalized corrosion performance relative to the base metal. But FSW&P of austenitic stainless steel requires significant tool forge axis force to produce a weld (or a run). Exploratory runs utilizing forge axis force control were conducted to investigate the minimum force required to achieve defect-free runs. The correlation between forge axis force and resultant plunge depth was also investigated. Furthermore, detailed microstructural characterization was conducted to display the microstructural variation within the nugget zone.

36 MATERIALS SCIENCE↗

Energy and exergy analysis of multi-stage vacuum membrane distillation integrated with mechanical vapor compression

Membrane distillation (MD) is a promising candidate for desalinating hypersaline brine, but its poor energy efficiency has remained a major barrier for widespread application. One possible solution to this issue is to recover the latent heat in the process. In this work, a multi-stage vacuum MD (MSVMD) was integrated with a mechanical vapor compressor (MVC) to enhance the latent heat recovery, and the energetic and exergetic performance of this integrated process was examined. A comprehensive energy and exergy analysis is provided to compare MSVMD and MSVMD-MVC processes for desalination of hypersaline brine. This analysis was conducted by examining the effect of the compression ratio on the energetic and exergetic performance, and the findings are reported in terms of specific thermal energy consumption (STEC), specific electricity consumption (SEC), and exergetic efficiency. The energy analysis shows that thermal energy consumption can be reduced as the compression ratio increases, due to the enhancement of latent heat recovery. The MSVMD-MVC process can be operated in a steady-state condition, without the need for thermal heat input; with STEC and SEC of 0 and 49 kWh/m 3 at the feed temperature of 50 °C and MVC compression ratio of 2.14. Moreover, exergy analysis demonstrates the efficacy of the eNRTL model in exergy calculation. Exergy destruction can be greatly reduced by increasing the compression ratio to an optimal value. For high salinity brine (124 g/L), MSVMD-MVC achieved a higher exergetic efficiency of 6.85%, compared to 2.42% in MSVMD. Furthermore, the result suggests that the application of MVC can intensify the energy efficiency and exergetic efficiency of the MSVMD system, although this process cannot outperform the current desalination technologies from the standard primary energy point of view.

42 ENGINEERING↗

Mechanical responses of 316L stainless steel printed by wire arc additive manufacturing with different thermal histories

In this paper, 316L stainless steel walls were printed using single-bead pass and multiple-bead pass wire arc additive manufacturing (WAAM), which represent the internal basket wall and external wall of a spent nuclear fuel (SNF) canister; respectively. Scanning electron microscopy (SEM) microstructure characterization and tensile tests at room temperature (21 °C) and elevated temperature (250 °C) were performed on specimens extracted along the length and height directions of the printed walls. Results showed that grain morphology, grain angles, and retained ferrite are different between the two printed walls, which received different heat input in WAAM. The single-bead pass printed wall exhibited higher yield strength than the multiple-bead pass printed wall because of more retained ferrite and larger portion of random-high angle boundaries (RHAB) grains.

Tang, Wei↗

Investigation of Cold Spray as a Dry Storage Canister Repair and Mitigation Tool

The lack of a permanent spent nuclear fuel repository means utilities are faced with extending licenses for dry cask storage systems (DCSS) canisters far beyond their original 20-year license period. DCSS canisters are made from austenitic stainless steels (SSs) and fabricated using fusion welds. High heat input and melting associated with fabrication welds causes material around the weld to be susceptible to chloride-induced stress corrosion cracking (CISCC). The purpose of the work reported here is to investigate the use of cold spray for repair and mitigation of CISCC in DCSS canisters to ensure integrity far beyond their original license period. This report presents an analysis of cold spray for canister life extension, a summary of related efforts, relevant technology down selections, work accomplished, and future efforts relative to use of cold spray for repair and mitigation of CISCC in DCSS canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

ON PROCESS STABILITY IN WAAM-CMT OF ALUMINUM ALLOYS

Wire-arc additive manufacturing (WAAM) has become a cost-efficient metal additive manufacturing process. However, depositing aluminum with WAAM is challenging due to its sensitivity to heat input (linear energy density), which can cause undesirable surface topology waviness if not controlled. Thus, a process window is needed that can produce stable geometry and deposition conditions while minimizing production times. In this study, 5183 aluminum alloy wire is used to deposit 10-layer walls with varying wire feed speeds (WFS) and traverse speeds (TS) (at a constant WFS/TS ratio) and varying interpass temperature (IPT). In-situ process data consisting of optical contact-tip-workpiece-distance (CTWD) and current/voltage measurements are collected to determine process condition stability throughout the build. Part geometry is measured using a 3D scanner and build porosity is characterized via digital X-ray. A process window is identified that produces stable surface topology and process conditions at a minimal production time.

aluminum alloy↗

Accelerated corrosion testing of cold spray coatings on 304L in chloride environments

Cold spray is an advanced metal manufacturing technique applied across many fields for a wide range of functions. Low heat input and compressive stresses induced into the substrate by the cold spray process makes it a promising choice for protective corrosion resistant coatings. One potential application for cold spray is as a protective coating against corrosion for spent nuclear fuel (SNF) interim dry storage canisters. As these canisters are currently stored at interim storage locations longer than originally intended, chloride induced stress corrosion cracking has been identified as a high priority knowledge gap, specifically with respect to prolonging or extending canister lifetimes ( Teague et al., 2019 ). The high deployability of cold spray, for which nozzles have been developed for application in constrained spaces, in conjunction with beneficial properties inherent to cold spray makes this a good candidate for a corrosion protection coating on SNF canisters. This work explores a pathway to rapidly down-select cold spray coatings for canisters by focusing on the corrosion properties. Specifically, this study examines the corrosion protection abilities of nickel and nickel-based alloy cold spray coatings on 304 L stainless steel in chloride rich environments through electrochemical scans and ferric chloride pitting tests (ASTM G48 Method A). It was shown that the porosity of the coating, the processing gas, material selection, and deformation in the substrate all impact the corrosion behavior of cold spray coatings and are areas where optimization could reduce potential materials degradation, enabling enhanced coatings development.

Karasz, Erin K.↗

Chloride-Induced Stress Corrosion Cracking of Friction Stir-Welded 304L Stainless Steel: Effect of Microstructure and Temperature

Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H2SO4 solution at room temperature and boiling MgCl2 solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H2SO4 solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl2 solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl2 solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H2SO4 solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal.

304L austenitic stainless steel↗

Reburning of Animal Waste Based Biomass with Coals for NO x Reduction, Part II: Dairy Biomass (DB) and Coal–DB Blends

Concentrated animal feeding operations (both slaughter and dairy cattle) lead to land, water, and air pollution if waste storage and handling systems are not effectively managed. At the same time, cattle biomass (CB), which includes both slaughter/feedlot biomass (FB) and dairy biomass (DB), have the potential to be a source of green energy at coal-fired power plants. Part I presented results on NOx reductions with pure FB or Coal: FB blends as reburn fuels. Part II deals with results from reburning with pure DB or Coal: DB blends as reburn fuels. A mixture of NG with a small amount of NH3 was used to generate the baseline NOx of 400–420 ppm (or 185–194 g/GJ). NOx emissions were found to be reduced by as much as 96% when reburning with FB. The effects of reburn fuel type, equivalence ratio (ER RBZ ) in the reburn zone, vitiated air, several injection configurations of reburn fuel and initial NO concentrations on NOx emissions were investigated. The ER RBZ shows a significant effect on the NOx reduction. The 20% heat input by reburning was the better operating condition for the long-term operation due to its ash production. The results reveal that reburn with DB fuels is an effective technology for NOx emission control when the initial NOx emission is higher than 275 ppm (or 127 g/GJ or 0.3 lb/MMBtu).

09 BIOMASS FUELS↗

In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion

Laser powder bed fusion (LPBF) is an additive manufacturing technology with the capability of printing complex metal parts directly from digital models. Between two available emission modes employed in LPBF printing systems, pulsed wave (PW) emission provides more control over the heat input compared to continuous wave (CW) emission, which is highly beneficial for printing parts with intricate features. However, parts printed with pulsed wave LPBF (PW-LPBF) commonly contain pores, which degrade their mechanical properties. In this study, we reveal pore formation mechanisms during PW-LPBF in real time by using an in-situ high-speed synchrotron x-ray imaging technique. We found that vapor depression collapse proceeds when the laser irradiation stops within one pulse, resulting in occasional pore formation during PW-LPBF. We also revealed that the melt ejection and rapid melt pool solidification during pulsed-wave laser melting resulted in cavity formation and subsequent formation of a pore pattern in the melted track. The pore formation dynamics revealed here may provide guidance on developing pore elimination approaches.

36 MATERIALS SCIENCE↗

AdditiveFOAM

AdditiveFOAM is a continuum heat transfer and fluid flow code for metal additive manufacturing developed on the OpenFOAM CFD Framework. The main components of AdditiveFOAM include: a dynamic heat source model representing heat input from independently moving beams; a robust and efficient thermodynamic solver for solid-liquid phase change in metal alloys; a library to export thermal data to ExaCA— a cellular automata (CA) code used for predicting solidification grain growth. By integrating these capabilities, AdditiveFOAM offers valuable insights into the process-structure relationships of metal additive manufacturing components.

Coleman, John [Oak Ridge National Laboratory (ORNL↗

Develop a Fast Analysis Solver for Welding Sequence Optimization

During the shipbuilding manufacturing process, materials are exposed to significant stresses, as induced both thermally and mechanically, that alter the intended design and significantly affect the production schedule, labor hours (fitting, welding, rework, etc.), and material structural performance. The type and magnitude of deformation of a given structure depends on many factors such as the material, thickness and quality of components, the process heat input, preheat and inter-pass temperatures, type and size of welds, welding sequence and direction, location, sequence, and degree of fixturing. Numerical simulations using finite element analysis (FEA) have long been used to analyze welding-induced structural distortion. For large assemblies, transient thermal elastic-plastic analysis (TEPA) can take days or weeks to run, and optimization of welding sequence is not feasible. Simplified analysis methods were developed to reduce computational time. However, it is challenging to use these techniques to fully optimize welding sequencing because of their applied simplifications in modeling weld details. A fast analysis solver that could be used by the shipbuilding industry is being developed for optimizing welding sequences by taking full advantage of modern GPU-based HPC hardware and incorporating patented acceleration schemes. The accelerated processing factors are up to 2200 times greater for large, multi-pass welded structures.

Yang, Yu-Ping↗

Flexible Operation of Natural Gas Power Plants in Texas: Startup and Shutdown Durations and Nitrogen Dioxide Emissions

This dataset provides insights into historical flexible operation of natural gas power plants in Texas, with a focus on startup and shutdown events. The dataset includes tables summarizing startup and shutdown durations as well as nitrogen oxide (NOx) emission factors during these events, and compares these emission factors with those observed during all other operating phases (referred to here as “steady-state operation”). The dataset is derived using the U.S. Environmental Protection Agency (EPA)’s Clean Air Markets Program Data (CAMPD). Historical hourly data from 2015–2024, including electricity generation, heat input, and NOx emission factors, are used for natural gas combined cycle units, combustion turbine units, and steam turbine units in Texas. This work was authored by the National Laboratory of the Rockies, operated by the Alliance for Energy Innovation, LLC, for the U.S Department of Energy (DOE) under contract no. DE-AC36-08GO28308. Funding was provided by the U.S. Department of Energy as part of its Grid Modernization Laboratory Consortium, a strategic partnership between DOE and the national laboratories to bring together leading experts, technologies, and resources to collaborate on the goal of modernizing the nation’s grid. The views expressed in the dataset do not necessarily represent the views of the DOE or the U.S. Government.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Additive manufacturing of ferritic/martensitic steel with improved high temperature strength

Techniques for using additive manufacturing (AM) to fabricate creep resistant ferritic/martensitic steel with improved high temperature strength are described. AM processing may be performed on Grade 91 steel powder. Beam powers from about 221 W to about 270 W may be used. Traverse rates from about 675 mm/s to about 825 mm/s may be used. Heat inputs ranging from about 55.7 J/mm3 to about 83.2 J/mm 3 may be produced. Creep resistant ferritic/martensitic steel, produced according to the present disclosure, has improved strain yield strength and ductility as compared to wrought steel.

Lienert, Thomas J.↗

Combined thermal energy storage and heat exchanger unit

The invention provides a method for storing heat and continuously generating electricity, the method comprising a phase change material; first fluid conduit in thermal communication with the phase change material wherein the first conduit is adapted to receive a first fluid; a second fluid conduit in thermal communication with the phase change material, wherein the second conduit is adapted to receive a second fluid; and a turbine in thermal communication with the second fluid. Also provided is a method for continuously charging the energy power block portion of a combined thermal energy storage and heat exchanger unit with heated fluid generated by concentrated solar power, the method comprising intermittently storing heat in a phase change material; and continually directing the heat from the phase change material to a turbine such that the phase change material buffers the turbine against inconsistent solar heat inputs.

France, David M.↗

Technology Strategy Assessment: Findings from Storage Innovations 2030 Thermal Energy Storage

The concept of thermal energy storage (TES) can be traced back to early 19th century, with the invention of the ice box to prevent butter from melting. Modern TES development began with building heating and cooling and concentrated solar thermal technologies for power generation in the early 1900s and late 1970s, respectively. TES systems provide many advantages compared with other long-duration energy storage (LDES) technologies, which include low costs, long operational lives, high energy density, synchronous power generation capability with inertia that inherently stabilizes the grid, and the ability to output both heat and electricity. TES Use Cases TES technologies can couple with most renewable energy systems, including wind, photovoltaic, and concentrated solar thermal energy, and can be used for heat-to-heat, heat-to-electricity, electricity-to-heat, and electricity-to-electricity (bidirectional electricity) applications. The three types of TES that have heat as an input or output are grouped together for the purposes of this report. Retrofitting retired thermal power plants can be a potential cost-effective option for TES with electricity output because they both use a similar thermal-to-electricity type of conversion. Additionally, TES can directly serve heat demand for buildings and industrial processes, displacing fossil fuels to achieve broad decarbonization. Bidirectional Electricity Figure 1 shows a bidirectional electricity TES (ETES) architecture that is emerging as a prime technology for LDES at a grid scale. The ETES technology can utilize existing TES technology infrastructures, has no geological limitations (such as mountains and water for pumped storage hydro, underground natural caverns for compressed-air energy storage, etc.), and is capable of deployment anywhere in the United States and the world for broad uses. Particularly, ETES technology can be placed at retired fossil-fueled thermal power plants to reuse decommissioned assets, protect job security in associated communities, and provide resilient and high-inertia (i.e., spinning) power to the grid. Heat Input and Output There also are many ways to integrate TES within heat-to-electricity, heat-to-heat, and electricity-to-heat applications, such as those used in concentrating solar power (CSP), buildings, district heating, and industry process heat applications. These categories can be further classified for low- and high-temperature applications. High-temperature thermal energy storage (HTTES) heat-to-electricity TES applications are currently associated with CSP deployments for power generation. TES with CSP has been deployed in the Southwestern United States with rich solar resources and has proved its value to the electric grid. Electricity-to-heat and heat-to-heat HTTES applications present great potential for decarbonizing energy-intensive industrial process heat applications [8, 9], such as iron ore processing, iron smelting, cement production, glass manufacturing, mineral processing, and chemical production. Some industrial processes require process heat at temperatures > 1,400°C, so HTTES can be utilized to reduce fuel consumption in those processes through fuel, oxidizer, and process material pre-heating. Thermal energy storage for augmenting existing industrial process heat applications makes a much more attractive economic case because the energy penalty due to thermal-to-electric conversion is eliminated. Co-located applications of power production and heat also can add to the value stacking of integrating utility-scale TES; however, these scenarios are very case specific and not practically possible in many cases. These constraints are primarily attributed to the existing infrastructure being designed, developed, and constructed for many decades around the most economically feasible technologies, such as electricity and a selection of fossil fuels for heat input. Low-temperature TES can be utilized for building and district heating and cooling, as well as some process heat applications in electricity-to-heat and heat-to-heat configurations. Lower temperature TES (LTTES) can be added to heat pump equipment (electric input), either directly interacting with the refrigerant in the condenser or evaporator, or through a secondary heat transfer fluid. It also can be integrated in the building envelope or within the ducts of the heating, ventilation, and air conditioning (HVAC) system. Cost-effective integration of TES into buildings adds significant cost, and it is one of the key barriers preventing the commercialization and deployment of TES. The optimal strategy for integrating TES with buildings has yet to be determined for various applications of TES. Nevertheless, thermal storage materials are far less costly per unit of energy stored than electricity storage materials. This means that thermal storage has the potential to reduce the cost to society of energy storage.

25 ENERGY STORAGE↗

Integration and Optimization of a Waste Heat Driven Organic Rankine Cycle for Power Generation in Wastewater Treatment Plants

The study focuses on achieving energy self-sufficiency in Wastewater Treatment Plants by proposing a comprehensive model for integrating, sizing, and optimizing an Organic Rankine Cycle system. The Organic Rankine Cycle system is designed to utilize waste heat from the gensets at As Samra Wastewater Treatment Plant in Jordan, where it will contribute to the overall electrical energy supply of the plant. Real data from As Samra Wastewater Treatment Plant is used to model and calculate the available waste heat using TRNSYS® software. The Organic Rankine Cycle model is then developed using ASPEN PLUS® software to explore the impact of operational parameters and determine their optimal values for maximizing the plant's energy profile. An economic analysis is conducted to assess the feasibility of the proposed model, considering system components, installation, operation, and maintenance costs. To optimize the Organic Rankine Cycle system, the study employs the Multi-Output Support Vector Regression technique to capture nonlinear relationships between independent variables (fluid type, turbine inlet pressure, turbine inlet temperature, turbine outlet pressure, and mass flow rate) and dependent variables (pump power input, waste heat input, and turbine specific work). The Osprey optimization algorithm is used to address the multi-objective optimization problem, with the proposed Pareto-based Osprey Optimization Algorithm and the Multi-Objective Particle Swarm Optimization technique being employed to evaluate critical performance and economic parameters such as system thermal efficiency, net power output, and the levelized cost of electricity. The results of the optimization strategies indicate that the M-SVR model's prediction accuracy is significantly improved after parameter optimization, with the model returning high R 2 and low Mean Square Error values of 0.991 and 0.00216, respectively. The Pareto-Based Osprey Optimization Algorithm optimizer identifies the best working fluid as Isobutane/Isopentane in a ratio of 66:34, with optimal turbine inlet pressure and temperature of 15 bars and 218 °C, respectively. In conclusion, the Organic Rankine Cycle model at these optimal conditions achieves a cycle efficiency of 19.93% and an Levelized Cost of Electricity value of 0.0353 USD/kWh.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗