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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Process Scale-Up of an Energy-Efficient Membrane Solvent Extraction Process for Rare Earth Recycling from Electronic Wastes

This study reports the process scale-up and long-term performance of an energy-efficient and cost-effective membrane solvent extraction (MSX) process for separation and recovery of high purity rare earth oxides (REOs) from scrap permanent magnets (SPMs). Here, the rare earth elements (REEs), including dysprosium, neodymium, and praseodymium, are recovered from SPMs using a neutral extractant, tetraoctyl diglycolamide (TODGA) embedded in a microporous polypropylene hollow fiber membrane module. The MSX process performance is demonstrated with bench scale module with membrane surface area of 1.4 m 2 to industrial scale modules with membrane surface area of up to 20 m2 to enable the processing of up to 1 ton month –1 of SPMs. The purity and the yield of the recovered REOs are >99.5 wt% and >95%, respectively. The average extraction rate of REOs is >10 g m –2 hr –1 . A skid of MSX system is assembled with a membrane area of 40 m 2 . The MSX skid successfully recovers REOs with a capacity of 300 kg REOs/month. Finally, it is determined that the organic phase containing the extractant maintains its performance up to 250 h. The results suggest that the MSX process is an economically viable and environmentally friendly process for separation and recovery of REOs from electronic wastes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Multimodal Analysis of Spatially Heterogeneous Microstructural Refinement and Softening Mechanisms in Three-Pass Friction Stir Processed Al4Si Alloy

Multiple thermally and thermomechanically induced microstructural refinement mechanisms can be activated in metallic alloys when subjected to solid phase processing methods such as friction stir processing (FSP). In this work, we provide detailed descriptions of the relationship between region-specific microstructural refinement mechanisms and the variation in microhardness, through a systematic and multimodal microstructural characterization of an FSP-processed 75% cold-rolled Al-4 at.% Si model binary alloy. Spatially resolved high-energy synchrotron X-ray diffraction, electron backscattered diffraction, and scanning transmission electron microscopy were used to understand the spatially heterogeneous microstructural evolution due to FSP. Results provide insights into how mechanisms such as static recovery, static recrystallization, dynamic recovery and recrystallization, geometric and continuous dynamic recrystallization, and particle-stimulated static or dynamic grain nucleation may occur heterogeneously in the microstructure as a function of the distance from the stir zone in processed alloys, directly influencing the degree of softening. The systematic analysis of microstructures and hardness in the FSP-processed model binary alloy given in this work highlights the rich microstructural domains that can be uniquely harnessed through solid phase processing of metallic alloys.

Al4Si, Friction Stir Processing, Geometric Dynamic↗
DOE OSTI2025

The R -process Alliance: Enrichment of r -process Elements in a Simulated Milky Way–like Galaxy

We study the formation of stars with varying amounts of heavy elements synthesized by the rapid neutron-capture process (r-process) based on our detailed cosmological zoom-in simulation of a Milky Way–like galaxy with an N-body/smoothed particle hydrodynamics code, asura. Most stars with no overabundance in r-process elements, as well as the strongly r-process-enhanced (RPE) r-II stars ([Eu/Fe] > +0.7), are formed in dwarf galaxies accreted by the Milky Way within the 6 Gyr after the Big Bang. In contrast, over half of the moderately enhanced r-I stars (+0.3 < [Eu/Fe] ≤ +0.7) are formed in the main in situ disk after 6 Gyr. Our results suggest that the fraction of r-I and r-II stars formed in disrupted dwarf galaxies is larger the higher their [Eu/Fe] is. Accordingly, the most strongly enhanced r-III stars ([Eu/Fe] > +2.0) are formed in accreted components. These results suggest that non-r-process-enhanced stars and r-II stars are mainly formed in low-mass dwarf galaxies that hosted either none or a single neutron star merger, while the r-I stars tend to form in the well-mixed in situ disk. We compare our findings with high-resolution spectroscopic observations of RPE metal-poor stars in the halo and dwarf galaxies, including those collected by the R-Process Alliance. We conclude that observed [Eu/Fe] and [Eu/Mg] ratios can be employed in chemical tagging of the Milky Way’s accretion history.

Chemical enrichment↗
DOE OSTI2018

Temperature-dependent selective oxidation processes for Ni-5Cr and Ni-4Al

The selective oxidation of Ni-5Cr and Ni-4Al alloys is evaluated during high (800°C) and low (420°C) temperature exposures with the oxygen partial pressure moderated by a Ni/NiO powder buffer. Internal oxidation of Cr and Al is observed throughout the matrix and at grain boundaries at 800°C accompanied by the ejection of Ni onto the surface for both. At 420°C, matrix internal oxidation was eliminated and only Ni-4Al exhibited intergranular (IG) oxidation. Surprisingly, a protective surface oxide rapidly formed for Ni-5Cr blocking IG oxidation. This is contradictory to results in 330–360°C hydrogenated water environments where both alloys show IG oxidation.

Ni-based alloys, preferential intergranular oxidat↗
DOE OSTI2022

An Adaptive Geometry-Free Thermo-Mechanical Model for Directed Energy Deposition Process Modeling

This presentation describes a novel, geometry-free thermo-mechanical model with adaptive subdomain con- struction to accurately predict the thermal conditions, distortions, and residual stresses throughout the directed energy deposition (DED) process. A novel finite element workflow is designed to con- duct the numerical analysis, based on the multi-app and data transfer capabilities in the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE). Unlike with traditional methods, the part geometry in this model is not predefined. Instead, it is a combined effect of the processing parameters and material properties. At each time step, the model utilizes a subdomain construction paradigm to model the material deposition. A specialized mesh adaptivity scheme is incorporated to provide an accurate prediction while reducing the overall computational cost. The results generated by the proposed model show general agreement with the experimental measurements for the single track scan with varying processing parameters and demonstrate reasonable predictions for higher material buildups.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A New Method for Optimizing Hot Processing Parameters of Mg-6.0Zn-0.5Mn-0.5Er Alloy Based on Kinetic Model of Dynamic Recrystallization and Processing Map

Hot deformation behavior of the cast-homogenized Mg-6.0Zn-0.5Mn-0.5Er alloy was studied using dynamic recrystallization (DRX) kinetic model and processing map. The compressing tests were conducted in the temperature range of 250-450 °C and strain rates of 0.001-1 s{sup −1}. According to the evolution of microstructures, under lower strain rates, the main DRX mechanism of Mg-6.0Zn-0.5Mn-0.5Er alloy is continuous DRX (CDRX); twinning induced DRX (TDRX) and CDRX both become the main DRX mechanism under higher strain rates. The DRX kinetics model of Mg-6.0Zn-0.5Mn-0.5Er alloy is calculated as X{sub DRX}=1−exp[−1.9463(((ε−ε{sub c})/(ε{sup ∗}))){sup 1.4608}], which is corresponding to the microstructure evolutions of DRX under different deformation conditions. The contour map of DRX was proposed based on the calculation results of DRX kinetics model. The processing maps are constructed to predict processing parameters of the alloy, and the predictability was evaluated combining with the contour map of DRX and dynamic materials model (DMM) processing map. It is deduced from the microstructures evolution and processing map that the optimum processing domain is mainly at 380-450 °C and 0.01-0.001 s{sup −1}, and 410-420 °C and 0.01-1 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization of the Fe-Co-1.5V soft ferromagnetic alloy processed by Laser Engineered Net Shaping (LENS)

Processing of the low workability Fe-Co-1.5V (Hiperco® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification, which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. In conclusion, magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco® alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multistage Surface-Heated Vacuum Membrane Distillation Process Enables High Water Recovery and Excellent Heat Utilization: A Modeling Study

Surface-heated membrane distillation (MD) enhances the energy efficiency of desalination by mitigating temperature polarization (TP). However, systematic investigations of larger scale, multistage, surface-heated MD system with high water recovery and heat recycling are limited. Here, we explore the design and performance of a multistage surface-heated vacuum MD (SHVMD) with heat recovery through a comprehensive finite difference model. In this process, the latent heat of condensation is recovered through an internal heat exchanger (HX) using the retentate from one stage as the condensing fluid for the next stage and an external HX using the feed as the condensing fluid. Model results show that surface heating enhances the performance compared to conventional vacuum MD (VMD). Specifically, in a six-stage SHVMD process, 54.44% water recovery and a gained output ratio (GOR) of 3.28 are achieved with a surface heat density of 2000 W m –2 , whereas a similar six-stage VMD process only reaches 18.19% water recovery and a GOR of 2.15. Mass and energy balances suggest that by mitigating TP, surface heating increases the latent heat trapped in vapor. The internal and external HXs capture and reuse the additional heat, which enhances the GOR values. We show for SHVMD that the hybrid internal/external heat recovery design can have GOR value 1.44 times higher than that of systems with only internal or external heat recovery. Furthermore, by only increasing six stages to eight stages, a GOR value as high as 4.35 is achieved. The results further show that surface heating can reduce the energy consumption of MD for brine concentration. As a result, the multistage SHVMD technology exhibits a promising potential for the management of brine from industrial plants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Nanodroplet processing platform for deep and quantitative proteome profiling of 10–100 mammalian cells

Nanoscale or single cell technologies are critical for biomedical applications. However, current mass spectrometry (MS)-based proteomic approaches require samples comprising a minimum of thousands of cells to provide in-depth profiling. Here, we report the development of a nanoPOTS (Nanodroplet Processing in One pot for Trace Samples) platform as a major advance in overall sensitivity. NanoPOTS dramatically enhances the efficiency and recovery of sample processing by downscaling processing volumes to <200 nL to minimize surface losses. When combined with ultrasensitive LC-MS, nanoPOTS allows identification of ~1500 to ~3,000 proteins from ~10 to ~140 cells, respectively. By incorporating the Match Between Runs algorithm of MaxQuant, >3000 proteins were consistently identified from as few as 10 cells. Furthermore, we demonstrate robust quantification of ~2400 proteins from single human pancreatic islet thin sections from type 1 diabetic and control donors, illustrating the application of nanoPOTS for spatially resolved proteome measurements from clinical tissues.

Environmental Molecular Sciences Laboratory↗
DOE OSTI2022

Kinetic processes of phase separation and aggregation behaviors in slot-die processed high efficiency Y6-based organic solar cells

Morphological optimization has proved to be one crucial factor contributing to the 19% efficiency of Y6-based organic solar cells (OSCs). Although the relationship between component miscibility and film morphology has been established, it has not been clarified how the film formation processes proceed, especially for methods compatible with large-area fabrication, i.e. slot-die coating, which restricts the further optimization of the morphology. Herein, we comprehensively investigate the effect of miscibility and the film-formation kinetic process on film morphology during processing with different solvents. A highest power conversion efficiency (PCE) of 17.38% can be obtained in a D18:Y6 device processed with slot-die coating in an open-air environment. However, due to their relatively poor miscibility, incorporating a trace amount of chlorobenzene (CB) into CF can sufficiently promote Y6 aggregation, leading to increased phase separation and thus the average PCE drops to 15.16%. In contrast, a PM6:Y6 blend shows insensitive changes in the kinetic process as well as the final morphology, and thus in the comparable PCEs when cast with different solvents, which is ascribed to their relatively good miscibility. As a result, this work provides scientific guidelines for device optimization by combining the intermediate gap from miscibility to kinetic process and their impact on final morphology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Impact of Timing in the Design Process on Students’ Application of Design for Additive Manufacturing Heuristics

The goal of this work is to study the way student designers use design for additive manufacturing (DfAM) rules or heuristics. It can be challenging for novice designers to create successful designs for additive manufacturing (AM), due to its recent surge in popularity and lack of formal education or training. A study was carried out to investigate the way novices apply DfAM heuristics when they receive them at different points in the design process. A design problem was presented to students, and three different groups of student participants were given a lecture on DfAM heuristics at three different points in the design process: before the initial design, between the initial design and redesign, and after the redesign. The novelty and quality of each of the resulting designs were evaluated. Results indicate that although the DfAM heuristics lecture had no impact on the overall quality of the designs generated, participants who were given the heuristics lecture after the initial design session produced designs that were better-suited for 3D printing in the second phase of the design activity. However, receiving this additional information appears to prevent students from creatively iterating upon their initial designs, as participants who received heuristic information between the design sessions experienced a decrease in novelty between the two sessions. Additionally, receiving the heuristics lecture increased all students’ perceptions of their ability to perform DfAM-related tasks. Furthermore, these results validate the practicality of design heuristics in lecture form as AM training tools while also emphasizing the importance of iteration in the design process.

computer-aided design↗
DOE OSTI2020

The ongoing need for high-resolution regional climate models: Process understanding and stakeholder information

Regional climate modeling addresses our need to understand and simulate climatic processes and phenomena unresolved in global models. High resolution models are generally more skillful in simulating extremes, such as heavy precipitation, strong winds, and severe storms. In addition, research has shown that fine-scale features such as mountains, coastlines, lakes, irrigation, land use, and urban heat islands can substantially influence a region’s climate and its response to changing forcings. Regional climate simulations explicitly simulating convection are now being performed, providing an opportunity to illuminate new physical behavior that previously was represented by parameterizations with large uncertainties. Regional and global models are both advancing toward higher resolution, as computational capacity increases. However, the resolution and ensemble size necessary to produce a sufficient statistical sample of these processes in global models has proven too costly for contemporary supercomputing systems. Regional climate models are thus indispensable tools that complement global models for understanding regional climate variability and change, and are critical for supporting societal responses to changing climate.

Gutowski, William↗
DOE OSTI2020

White Paper to Justify the Use of Strip Effluent in the Defense Waste Processing Facility During Slurry Mix Evaporator Processing

At the request of Savannah River Remediation (SRR), a white paper was written to assess whether it would be acceptable to process Strip Effluent (SE) in both the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) in the Defense Waste Processing Facility (DWPF) for the nitric-glycolic acid flowsheet. Savannah River National Laboratory (SRNL) experimental data and DWPF Sludge Batch 9 (SB9) process data was reviewed, looking at batches which included Precipitate Reactor Feed Tank (PRFT) and/or Strip Effluent Feed Tank (SEFT) feeds that led to long processing times. These batches were reviewed looking for processing problems such as melter feed trips, foamovers, heating rod or steam coil fouling, missed Reduction/Oxidation (REDOX) targets, and other process anomalies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Process-microstructure relationship of laser processed thermoelectric material Bi2Te3

Additive manufacturing allows fabrication of custom-shaped thermoelectric materials while minimizing waste, reducing processing steps, and maximizing integration compared to conventional methods. Establishing the process-structure-property relationship of laser additive manufactured thermoelectric materials facilitates enhanced process control and thermoelectric performance. This research focuses on laser processing of bismuth telluride (Bi 2 Te 3 ), a well-established thermoelectric material for low temperature applications. Single melt tracks under various parameters (laser power, scan speed and number of scans) were processed on Bi 2 Te 3 powder compacts. A detailed analysis of the transition in the melting mode, grain growth, balling formation, and elemental composition is provided. Rapid melting and solidification of Bi 2 Te 3 resulted in fine-grained microstructure with preferential grain growth along the direction of the temperature gradient. Experimental results were corroborated with simulations for melt pool dimensions as well as grain morphology transitions resulting from the relationship between temperature gradient and solidification rate. Samples processed at 25 W, 350 mm/s with 5 scans resulted in minimized balling and porosity, along with columnar grains having a high density of dislocations.

Oztan, Cagri↗
NASA NTRS1991

Thermochemical analysis of chemical processes relevant to the stability and processing of SiC-reinforced Si3N4 composite

Chemical processes relevant to the stability and processing of SiC-reinforced Si3N4 composites have been examined from thermochemical considerations. The thermodynamic stabilities of various interfaces, such as SiC-Si3N4, SiC-Si3N4-Si2ON2, and SiC-Si3N4-SiO2, have been examined as a function of temperature, and the temperatures above which these interfaces become unstable have been calculated. The degradation of SiC during the processing of the composite has been examined. The processing routes considered in this study include the reaction bonded silicon nitride (RBSN) process and the pressure-assisted sintering processes with suitable sintering additives.

Misra, Ajay K.↗