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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 OSTI2018

Structural Studies of Amorphous Materials by Fluctuation Electron Microscopy

Fluctuation Electron Microscopy (FEM) is a technique that examines the fluctuations in electron scattering across a uniformly thin amorphous sample. The statistics of the intensity fluctuations, mean and variance, reveal any underlying medium-range order present in the structure. The goals of this project were: (1) To determine the fundamentals of the scattering physics that gives rise to the variance signal in fluctuation electron microscopy (FEM); (2) To use these discoveries to find ways to quantify FEM; (3) To apply the FEM method to interesting and technologically important families of amorphous materials, particularly those with important applications in energy-related processes. Excellent progress was made in items (1) and (2). In stage (3) we did not examine the metamict zircons, as proposed. Instead, we examined films of polycrystalline and amorphous semi-conducting diamond. Significant accomplishments are: (1) A Reverse Monte Carlo procedure was successfully implemented to invert FEM data into a structural model. This is computer-intensive, but it demonstrated that diffraction and FEM data from amorphous silicon are most consistent with a paracrystallite model. This means that there is more diamond-like topology present in amorphous silicon than is predicted by the continuous random network model. (2) There is significant displacement decoherence arising in diffraction from amorphous silicon and carbon. The samples are being bombarded by the electron beam and atoms do not stay still while being irradiated – much more than was formerly understood. The atom motions cause the destructive and constructive interferences in the diffraction pattern to fluctuate with time, and it is the time-averaged speckle that is being measured. The variance is reduced by a factor m, 4 ≤ m ≤ 1000, relative to that predicted by kinematical scattering theory. (3) Speckle intensity obeys a gamma distribution, where the mean intensity $ \overline{I}\ $ and m are the two parameters governing the shape of the gamma distribution profile. m is determined by the illumination spatial coherence, which is normally very high, and mostly by the displacement decoherence within the sample. (4) Amorphous materials are more affected by the electron beam than are crystalline materials. Different samples exhibit different disruptibility, as measured by the effective values of m that fit the data. (5) Understanding the origin of the displacement decoherence better should lead to efficient methods for computing the observed variance from amorphous materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimal Header Design for Diffusion Bonded Heat Exchangers

Microchannel heat exchangers have seen increasing adoption in many high-pressure applications in recent decades but are subject to particulate fouling from the relatively small channel size compared to traditional designs. Typical cleaning methods require process shutdown, heat exchanger removal, cleaning, then reassembly. The objective of this project was to refine and transfer technology to enable header design improvements for Cleaning-in-Place (CIP), allowing for reduced/negligible process interruption for the cleaning process. The technology transfer was from Sandia National Laboratories (Sandia) to Vacuum Process Engineering, Inc. (VPE). This primary purpose of CIP was developed while considering channel flow uniformity and heat exchanger cost. The project phases were to 1) capture and define potential improvement options, 2) evaluate options with both simulation and experiments, and 3) transfer design knowledge to the industry partner. These efforts resulted in improved header designs from the first known focused effort in this area. The improved designs will help the entire microchannel heat exchanger field that has applications in supercritical CO 2 power cycles, hydrogen (fuel cell) vehicle fueling, liquified natural gas processing, and more.

42 ENGINEERING↗
DOE OSTI2024

CRADA Number NFE-21-08827 with DayLyte, Inc. (CRADA Final Report)

DayLyte Batteries is developing an aqueous Sodium-Air battery made with abundant materials while being half to a third the weight of Li-ion to power electric aircraft, electric vehicles and provide renewable energy on demand. To make this battery practical, DayLyte is developing a thin film ceramic Nasicon solid electrolyte amenable to rapid scaleup as well as a protective coating that will protect the solid electrolyte from 50wt% NaOH during the battery’s end-of-discharge while still allowing Na-ions to pass back and forth. If the thin film solid electrolyte and stable coating can be developed it will open the world to step change in battery performance all while not sacrificing the environment on the way. The project was designed to first focus on making and characterizing the Nasicon membrane followed by measuring its electrochemical performance, then assembling a full cell, optimizing its NaOH stability and then optimize the overall prototype design. Over the past two years, we have significantly improved the Nasicon film uniformity, demonstrated protective ligands that are stable in 50wt% NaOH by measuring no mass change with a quartz crystal microbalance, tested different heating methods like tube furnace and rapid heating and developed glassy carbon coatings on the current collector to prevent Nasicon-current collector alloying. We have found that getting film uniformity as measured by electrochemical impedance spectroscopy (EIS) is difficult because of different factors like surface roughness, deposition uniformity and heat treatment time and uniformity. The glassy carbon coating should significantly reduce the surface roughness and by tuning the coating conditions the film deposition uniformity improves and using an automated heating method should lead to much improved film uniformity.

25 ENERGY STORAGE↗
DOE OSTI2019

Microwave Irradiation Intensified Process for Scalable Functional Device Assembly

The environment pollution is a serious issue worldwide for human beings, which calls for ever-increasing demand towards environmental protection. Efficient enabling and utilization of various functional devices represent an essential solution to pursue the environment sustainability. Nanotechnology is emerging as an effective approach to improve the efficiency of functional devices for a variety of environmental applications. For example, the nanomaterials-based catalysts are being widely used in air pollution control, enabling catalysts with significantly enhanced performance. Scalable integration of functional nanostructural entities such as nanoparticles, nanowires, nanosheets into applicable three-dimensional (3-D) platform holds the keys of industrial-relevant manufacture of high-efficiency catalytic devices for emission control. Among all the integration approaches, the wet-chemical based integration is one of the top options due to its advantages in low-cost, flexibility in substrate geometry and composition, ease of operation, and high repeatability. The wet-chemical based processes usually require continuous heating to initiate the chemical reactions, which is regularly achieved by conventional resistive heating. However, such conventional heating method is plaqued by a poor heating efficiency. Moreover, the conventional heating is not suitable for those substrates with three-dimensional (3D) or complex geometry since it hardly provides sufficient heat transfer and mass transport within substrates, leading to poor uniformity of nanostructure deposition and low production rate. Thus, there is urgent demand to develop high-efficiency wet-chemical based integration strategy for nanostructured functional devices. In this project, a novel microwave-irradiation-intensified hydrothermal manufacturing process was developed for scalable manufacture of nanostructured monolithic catalytic devices. A wide array of metal oxide nanostructured coatings has been in situ grown on various 3D substrates for emission control applicaitons such as cordierite honeycombs and silicon carbide honeycomb. The growth efficiency, production rate, and distribution uniformity of nanostructure coatings obtained from microwave heating and conventional heating are investigated, which reveals the boosting effect of microwave irradiation on hydrothermal reactions. The silicon carbide honeycomb is found to be more favorable to microwave adsorption in contrast to cordierite honeycomb, and the corresponding reaction mechanism is studied. The obtained catalysts are used for catalytic oxidation of Volatile Organic Compounds (VOCs), showing excellent catalytic performance at low temperature for various compounds. As the proof of concept, the design of integrated manufacturing system for the microwave irradiation assisted continuous production of nanostructure array based monolithic catalysts is presented, which holds the key to mass production of monolithic catalysts in near future.

42 ENGINEERING↗
DOE OSTI2024

Designing Track for Electrospinning Unit and Cost-Effective Laser Scanning System

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
DOE OSTI2024

Designing a track for an electrospinning unit and cost-effective laser scanning system

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
DOE OSTI2025

Assessment of Self-interrogation Safeguards Signatures for Pebble Bed Reactor Fuel

New reactor designs, such as pebble-bed reactors, present challenges for the safeguarding of fissile material. Due to the multi-pass fuel circulation design and the non-uniform path a pebble may traverse through a pebble-bed reactor, there will be variations in the irradiation history of spent fuel pebbles. The standard approach of estimating actinide quantities based on fission gamma spectra or neutron emission paired with depletion modeling may yield uncertainties too large for safeguards and material accountancy. This project investigated, through modeling and experimentation, the potential of neutron self-interrogation of spent fuel pebbles as an innovative method to implement materials accountability. As an example, our feasibility studies indicate that the mass of U-235, U-238, Pu-239 and Pu-241 can be predicted to 4.1, 0.86, 13 and 13 % accuracy, respectively, when measuring 100 closely packed end-of-life spent fuel pebbles over approximately 12 days using a 4π counting geometry.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1992

Aeroelastic stability analyses of two counter rotating propfan designs for a cruise missile model

Aeroelastic stability analyses were performed to insure structural integrity of two counterrotating propfan blade designs for a NAVY/Air Force/NASA cruise missile model wind tunnel test. This analysis predicted if the propfan designs would be flutter free at the operating conditions of the wind tunnel test. Calculated stability results are presented for the two blade designs with rotational speed and Mach number as the parameters. A aeroelastic analysis code ASTROP2 (Aeroelastic Stability and Response of Propulsion Systems - 2 Dimensional Analysis), developed at LeRC, was used in this project. The aeroelastic analysis is a modal method and uses the combination of a finite element structural model and two dimensional steady and unsteady cascade aerodynamic models. This code was developed to analyze single rotation propfans but was modified and applied to counterrotating propfans for the present work. Modifications were made to transform the geometry and rotation of the aft rotor to the same reference frame as the forward rotor, to input a non-uniform inflow into the rotor being analyzed, and to automatically converge to the least stable aeroelastic mode.

Mahajan, Aparajit J.↗
NASA NTRS1992

Minimization of the vibration energy of thin-plate structure

An optimization method is proposed to reduce the vibration of thin plate structures. The method is based on a finite element shell analysis, a modal analysis, and a structural optimization method. In the finite element analysis, a triangular shell element with 18 dof is used. In the optimization, the overall vibration energy of the structure is adopted as the objective function, and it is minimized at the given exciting frequency by varying the thickness of the elements. The technique of modal analysis is used to derive the sensitivity of the vibration energy with respect to the design variables. The sensitivity is represented by the sensitivities of both eigenvalues and eigenvectors. The optimum value is computed by the gradient projection method and a unidimensional search procedure under the constraint condition of constant weight. A computer code, based on the proposed method, is developed and is applied to design problems using a beam and a plate as test cases. It is confirmed that the vibration energy is reduced at the given exciting frequency. For the beam excited by a frequency slightly less than the fundamental natural frequency, the optimized shape is close to the beam of uniform strength.

Inoue, Katsumi↗
NASA NTRS2017

Improving Estimation of Ground Casualty Risk From Reentering Space Objects

A recent improvement to the long-term estimation of ground casualties from reentering space debris is the further refinement and update to the human population distribution. Previous human population distributions were based on global totals with simple scaling factors for future years, or a coarse grid of population counts in a subset of the world's countries, each cell having its own projected growth rate. The newest population model includes a 5-fold refinement in both latitude and longitude resolution. All areas along a single latitude are combined to form a global population distribution as a function of latitude, creating a more accurate population estimation based on non-uniform growth at the country and area levels. Previous risk probability calculations used simplifying assumptions that did not account for the ellipsoidal nature of the Earth. The new method uses first, a simple analytical method to estimate the amount of time spent above each latitude band for a debris object with a given orbit inclination and second, a more complex numerical method that incorporates the effects of a non-spherical Earth. These new results are compared with the prior models to assess the magnitude of the effects on reentry casualty risk.

Ostrom, Chris L.↗
NASA NTRS2017

Improving Estimation of Ground Casualty Risk from Reentering Space Objects

A recent improvement to the long-term estimation of ground casualties from reentering space debris is the further refinement and update to the human population distribution. Previous human population distributions were based on global totals with simple scaling factors for future years, or a coarse grid of population counts in a subset of the world's countries, each cell having its own projected growth rate. The newest population model includes a 5-fold refinement in both latitude and longitude resolution. All areas along a single latitude are combined to form a global population distribution as a function of latitude, creating a more accurate population estimation based on non-uniform growth at the country and area levels. Previous risk probability calculations used simplifying assumptions that did not account for the ellipsoidal nature of the earth. The new method uses first, a simple analytical method to estimate the amount of time spent above each latitude band for a debris object with a given orbit inclination, and second, a more complex numerical method that incorporates the effects of a non-spherical Earth. These new results are compared with the prior models to assess the magnitude of the effects on reentry casualty risk.

Ostrom, C.↗
DOE OSTI2019

Metallic Low-Level Waste (LLW) Handling Options: An Optimal Life cycle-Based Approach for North American Operations - 19413

Daily activities associated with nuclear power plant operations produce large volumes of low-level contaminated waste. During operation, a small percentage of this low-level waste is metallic (< 1% by volume). However, this figure increases materially when a facility is finally decommissioned, with approximately 1000 m{sup 3} of contaminated metal waste generated for every 1 GW decommissioned (13% by volume). With global nuclear decommissioning efforts expected to increase until 2050, the amount of low-level metallic waste generated is expected to increase the global inventory by over an order of magnitude. The high cost of conventional surface storage and burial of radioactive metal, coupled with the projected increase in low-level metallic waste volumes provides strong incentive to identify cost-effective waste management solutions. Surface decontamination and thermal methods are proven options for decontaminating low-level metallic waste. Surface decontamination processes include chemical, electrochemical, or mechanical methods, which are used to remove contamination from exposed layers of metal. Surface decontamination is most effective when metal has low levels of activity localized on the outer layers. When the activity is more uniformly distributed in the metal (or the geometry is complex), alternative methods such as thermal decontamination are required. In the thermal decontamination process, contaminated scrap metal is melted in a furnace and held in a molten state for a period of time while the radioactive material is separated out through gravity. Radioactive material reports to slag which is handled separately, or to the exhaust which is handled using conventional gas handling technologies. Thermal methods of decontamination involving metal melting present an opportunity to reduce long-term storage cost with a reduction in waste volume, along with the opportunity to reuse the decontaminated metal. Methods for dealing with metallic low-level waste from nuclear facilities vary extensively across the globe. The approach employed at any given site may be set by a host of factors ranging from regulatory influence, public perception, local economics, available geology for underground storage and often, precedent established long ago by early operations. This paper examines several low-level metallic waste handling options including techniques for surface decontamination and metal melting, as well as a combination of both. The various methods are categorized according to their suitability for waste characterization and local/global installations. The effectiveness of each option is benchmarked against a range of criteria, including capital and operating costs, environmental impact, overall sustainability and risk management issues. The overall objective of this paper is to develop a methodology for determining the most beneficial low-level metallic waste management strategy for a facility once the quantity, type and nature of the waste is established on a long-term basis. It is the authors' hope that the methodology can be used as a tool to test a facility's current plans (which are primarily focused on long-term storage) and identify areas for optimization with an emphasis on overall cost and environmental footprint reduction. The trend towards long term planning to handle large amounts of contaminated metal, along with obtaining a social license to implement a sustainable waste management solution, are key decision-making variables that will be discussed in relation to the LLW handling options presented in this paper. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Beam steering characteristics of highly directive photoconductive dipole phased array antenna for terahertz imaging application

In this paper, the beam-steering characteristics of photoconductive dipole phased array antenna configuration at 1.95 THz is presented. The proposed array antenna configuration with frequency selective surface favourably improves its gain and directivity which is useful to upsurge the imaging capabilities to address the deliberations such as limited depth-of-field (DoF) and size-weight-and-power of the THz source for imaging applications. These are important considerations for applications like stand-off imaging and surveillance of moving targets where the high angular resolution as well as extended DoF are the important parameters for successful detection of concealed explosives. The projected planar profile and compact highly directive (2×2) small-gap photoconductive dipole phased array antenna can be castoff for the exposure of concealed explosives such as RDX, TNT, and HMX which illustrate their substantial spectral absorption fingerprints in terahertz (1.4–2.2 THz) regime of the spectrum. A simple method of beam-steering has been explored based on phase controlled optical excitation of highly directive small-gap photoconductive dipole array antenna. Further, the effects of uniform progressive phase shift on the beam-steering of uniform linear array (along x-axis) as well as planar array (x-axis and y-axis) is investigated.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Cold Sintered Ceramics and Cements for Part Encapsulation

In this project, ceramic encapsulation materials were studied for high temperature (>~°500 C) applications where typical polymer encapsulants are unstable. A new low temperature (<~°200 C) method of processing ceramics, the cold sintering process was examined. Additionally, commercially available high temperature ceramic cements were investigated. In both cases, the mechanical strengths of available materials are less than desired (i.e., desired strengths similar to Si 3 N 4 ), limiting applicability. Composite designs to increase mechanical strength are suggested. Additionally, non-uniformities in stresses and densification while embedding alumina sheets in encapsulants via cold sintering using uni-axial pressing led to fracture of sheets, and an alternative iso-static based approach is recommended for future studies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Advanced electrode manufacturing to enable low cost PEM electrolysis

A critical challenge for the implementation of proton exchange membrane (PEM)-based water electrolyzers for the H2@Scale vision is the capital cost, which is largely driven by related factors of overdesign and highly manual legacy manufacturing methods. Typical electrolyzer cells have an order of magnitude higher membrane thickness and catalyst loading vs. fuel cells, in part because the manufacturing methods being used are not capable of producing uniform and reliable electrodes on thin membranes with low loading. Advanced electrode manufacturing is therefore the key enabler to reduce the cost of the electrolyzer stack, particularly roll-to-roll (R2R) manufacturing of catalyst coated layers (CCLs) and catalyst coated membranes (CCMs). The electrolyzer manufacturing process still relies on traditional sheet-to-sheet (S2S) processes, which requires intensive labor to make parts to meet the specification requirements. This project leverages fuel cell expertise (GM) with Proton’s knowledge of electrolyzer components to develop the electrocatalyst ink formulations and coating processes using slot die (ORNL) and gravure (NREL) coatings, with proof of concept at the pilot-scale (Kodak).

08 HYDROGEN↗
NASA NTRS1998

Development of a Woven-Grid Quasi-Bipolar Battery

This report describes an analytical and experimental investigation of AeroVironment's Quasi-Bipolar battery concept. The modelling/battery design part of the study demonstrates that there is a trade-off between thermal and specified electrical performance. Even so, quasi-bipolar batteries can be designed, with ten times better thermal uniformity, that meet or exceed current state-of-the-art hybrid-electric vehicle battery pack performance, even using the same active materials. The thermal uniformity, power, and energy for these quasi-bipolar battery packs is projected to be very good. The experimental part of the investigation demonstrates the concept of the quasi-bipolar plate applied to a lead foil current collector wrapping around two sides of an inexpensive plastic film core. Approximately 50 quasi-biplate samples were fabricated using a hot laminating press. Hot lamination with "texture" between the plastic and lead shows some promise as a low cost method for fabricating the plates. Five of these plates were assembled into two cells plus one two-cell battery. Data from these test cells were compared with existing data for similar true bipolar batteries. The positive side of the plates exhibited corrosion where not protected by the active material.

Tokumaru, P.↗
NASA NTRS2012

Quantitative Global Heat Transfer in a Mach-6 Quiet Tunnel

This project developed quantitative methods for obtaining heat transfer from temperature sensitive paint (TSP) measurements in the Mach-6 quiet tunnel at Purdue, which is a Ludwieg tube with a downstream valve, moderately-short flow duration and low levels of heat transfer. Previous difficulties with inferring heat transfer from TSP in the Mach-6 quiet tunnel were traced to (1) the large transient heat transfer that occurs during the unusually long tunnel startup and shutdown, (2) the non-uniform thickness of the insulating coating, (3) inconsistencies and imperfections in the painting process and (4) the low levels of heat transfer observed on slender models at typical stagnation temperatures near 430K. Repeated measurements were conducted on 7 degree-half-angle sharp circular cones at zero angle of attack in order to evaluate the techniques, isolate the problems and identify solutions. An attempt at developing a two-color TSP method is also summarized.

Sullivan, John P.↗
DOE OSTI2023

Cybersecurity Platform and Certification Framework Development for Extreme Fast Charging (XFC)-Integrated Charging Ecosystem (Final Project Report)

This report summarizes a pioneering effort in Electric Vehicle charging infrastructure ecosystem cybersecurity requirements, assessment methodologies, functional verification, as well as embodiment of the key technologies in the form of hardware and software tools being made available to the public. EPRI led a team of experts, as well as a stakeholder coalition encompassing all key actors in the EV charging infrastructure ecosystem that includes eXtreme Fast Charging (XFC) equipment (defined as 200kW or above). EV charging infrastructure in the United States is a patchwork of networks that have continued to grow organically and have been designed to serve the charging needs of the EV owners, who are their customers. In doing so, each network provider, as well as their connected entities such as the cloud Electric Vehicle Service Providers or EVSPs, utility back office, utility AMI networks, payment networks, as well as Original Equipment Manufacturer (EV manufacturer) telematics networks, have designed systems that may work well individually, but no single entity is responsible for the entire ecosystem to be secure in terms of data exchange. Furthermore, there is no uniformity in how each actor has implemented the cybersecurity requirements since no system-wide cybersecurity requirements existed prior to this project. The final project report describes the technical approach guided by the EV charging infrastructure cybersecurity working group, convened specifically for this project. The technical approach included definition of requirements at the ecosystem level, treated as a ‘system of systems’, and then passed down to individual systems (EVSE, EV, cloud EVSP, utility, and the payment networks), followed by developing the cybersecurity risk and vulnerability assessment methods, that were later applied to real-world cyber-physical systems at EPRI, ANL, and NREL laboratories, to validate both the process and the results. Finally, in a spotlight over the most vulnerable equipment, which is the EV charge station (AC or DC), the team developed a multi-layer cybersecurity implementation in the embedded domain embodied by the open-source Secure Network Interface Card (SNIC) demonstrating the various ways in which the infrastructure can be secured protecting against the identified attack surfaces. Finally, the entire process of EV infrastructure cybersecurity assessment was encapsulated in the Electric Vehicle Charging Cybersecurity Management (EVC2M) online GUI-based tool, that is expected to be released to the public. The report presents the objectives, the technical approach, the key results, and recommendations for future work.

24 POWER TRANSMISSION AND DISTRIBUTION↗