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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

Design optimization of an additively manufactured prototype recuperator for supercritical CO 2 power cycles

Supercritical CO 2 (sCO 2 ) power cycles are being developed due to their potential for high efficiency and reduced capital cost. It is necessary that these recuperators operate at high pressures and temperatures, up to 30 MPa and 900 K, with effectiveness values > 95% and pressure drops <1% to achieve high cycle efficiencies. Moreover, it is also necessary to have reasonable cost recuperators to control the capital costs of the sCO 2 power cycles. In this study, a Plate Pin-Fin (PPF) heat exchanger has been proposed as an sCO 2 recuperator. This preliminary recuperator design leverages capabilities enabled by additive manufacturing. Although the PPF design has characteristics similar to those of a plate heat exchanger, small diameter and relatively long fins are used to increase surface area, enhance heat transfer, and provide structural support for the partition plates that separate the fluid streams. Existing correlations for heat transfer and pressure drop were adapted for the PPF heat exchanger. These correlations were implemented in a 1D analytical model and used for the optimization of a 5-kW th high temperature recuperator for an indirect sCO 2 cycle by varying the design parameters to minimize the quantity of material required. A 3D conjugate heat transfer numerical simulations were conducted to validate the heat transfer and pressure loss correlations. A steepest descent method was used to minimize heat exchanger mass for a 5-kW prototype recuperator subject to a maximum specified pressure drop. Additionally, the design analysis indicated that an optimum PPF recuperator would be attained for the minimum allowable pin transverse spacing, minimum pin width, minimum pin height and near maximum cell aspect ratio. Moreover, at a low material requirement of 0.216 kg/kW and a pressure drop, which is almost five times lower than the allowable pressure drop design target, the optimized PPF heat exchanger has the high potential to be an alternative to a printed circuit heat exchanger, which is a conservative design basis for the current state-of-the-art sCO 2 recuperators.

42 ENGINEERING↗
DOE OSTI2020

High-precision shock equation of state measurements for metallic fluid carbon between 15 and 20 Mbar

Diamond is an efficient ablator material to convert the energy of high-power giant lasers into ablation pressure with applications for High-Energy-Density (HED) science, planetary science, and Inertial Confinement Fusion (ICF) research at the National Ignition Facility (NIF). Unfortunately, current theoretical equation of state models cannot reproduce all the observed experimental data in the multi-megabar regime particularly relevant for HED and ICF research. New experimental data on the behavior of carbon at extreme pressures and temperatures are, therefore, essential to improve our predictive capability to design and analyze dynamic compression experiments for HED or ICF research and build improved equation of state models in the future. In this paper, we report high-precision laser-driven shock compression measurements on diamond single crystals at the Omega Laser Facility. Using ultrafast Doppler optical Velocimetry Interferometer System for Any Reflector (VISAR) to track the leading shock front and a quartz plate as an in situ reference, we obtain relative pressure-density shock equation-of-state measurements between 15 and 20 Mbar with an impedance-matching procedure. We also report shock-and-release measurements in a spherical geometry at the NIF. The new data provide tight constraints on the compressibility of warm dense carbon along the Hugoniot of full density diamond, allowing us to discriminate between existing theoretical equation-of-state models. We find that both LLNL LEOS 9061 and LANL Sesame 7835 models capture well the shock compressibility in the explored range. LANL Sesame 7835 also reproduces well the observed shock-and-release behavior of diamond near 10–20 Mbar.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Efficient Lithium Metal Cycling over a Wide Range of Pressures from an Anion-Derived Solid-Electrolyte Interphase Framework

Advanced electrolytes were developed to improve the cyclability of lithium (Li) metal anodes, yet their working mechanisms remain unclear. Here, we study the Li cycling performance under different pressures in a 1 M Li bis(fluorosulfonyl)imide/fluorinated 1,4-dimethoxybutane electrolyte. A consistently long cycle life is achieved over a wide range of pressures (30–600 psi). We find that this is due to a completely different Li plating mode with more favorable deposition morphologies compared to that in a conventional carbonate electrolyte, which exhibits increasing cycle stability with increased pressure. We show that this is enabled by the properties of an anion-derived residual solid-electrolyte interphase (rSEI) framework on the electrode surface, an undercharacterized structure with profound implications for Li metal cycling. This anion-derived rSEI chemistry is likely the key to a prolonged cycle life of Li metal batteries and should be vigorously addressed in future electrolyte designs.

25 ENERGY STORAGE↗
DOE OSTI2023

Influence of processing on secondary phase formation and microstructural evolution at U-10Mo alloy and Zr interlayer interfaces

Thermo-mechanical processing of uranium-10 wt. % molybdenum (U-10Mo) fuel plates leads to microstructure changes at the U-10Mo/Zr interfaces. Secondary phases formed at this interface are particularly important to interfacial bond strength, process optimization, and maintaining structural integrity of the U-10Mo fuel plates during irradiation. In this work, we determined the phases and phase transformation products occurring at the interface of the U-10Mo fuel and Zr interlayer when the fuel plate is subjected to short and long hot isostatic pressure times. Interfacial morphology, structure and composition of phases formed, and relative hardness across the U-10Mo/Zr interfaces were studied using a multi-length scale, multi-modal characterization approach involving electron microscopy, atom probe tomography, and atomic force microscopy. Here, results highlight that the extent of phase transformations, secondary phase formation, and hardness variability across interfaces can be controlled by modifying processing parameters. Phase diagram construction and thermodynamic calculations were performed using the Thermocalc software to identify expected phases formed at interfaces during the maximum hold temperature of 560 °C experienced during HIP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Reshock analysis for PMMA driven above the threshold for chemical decomposition

Polymethyl methacrylate (PMMA) is a transparent thermoplastic often used in shock compression science. Previous proceedings (AIP Conf. Proc. 845, 131 (2006)) described plate impact experiments in which PMMA was reshocked to pressures of up to ~130 GPa, well above that at which it decomposes on its principal Hugoniot. Because some of the conclusions of the original analysis were surprising, the results were reanalyzed in a later proceeding (ibid. 1426, 771 (2012)). In addition to our own reanalysis of the data, we performed hydrodynamic simulations of the experiments based on a new equation of state for PMMA shocked above its threshold for decomposition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Fuel/Basket Degradation Modeling Summary

This report documents the activities in a preliminary phase of development for three models: 1) waste package breach model, 2) fuel/basket degradation model, and 3) dual-purpose canister (DPC) crush model. The waste package breach model describes the coupling of mass flow, heat transport, and canister shell deformation in response to a heat-generating (criticality) event. The fuel/basket degradation model describes potential weakening and disaggregation of the DPC structure from corrosion, possibly accelerated by seismic ground motion. Progressively degraded three-dimensional (3D) configurations of the fuel, basket, and shell are generated for future analysis of reactivity (with as-loaded DPC fuel characteristics). Another important application for the fuel/basket degradation model is validation of the two stylized degradation cases currently being used by other investigators for analysis of the as-loaded DPC inventory under disposal conditions. The DPC crush model investigates stability of a typical DPC after breach of the disposal overpack allows fluids from the repository near-field environment to penetrate and externally pressurize the canister shell. Preliminary results show that large deformation of the DPC could occur for external pressure on the order of 10 to 15 MPa, or the shell could be stable (not collapse) with pressure of 20 MPa or greater if the basket plates are fully welded at the connections.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

A theoretical/computational framework to measure SiO2 and MgO viscosity at high pressure

The convection of the mantle of Earth and super-Earths is important for many terrestrial phenomena, from plate tectonics to outgassing. Rheological properties, such as viscosity, regulate the transport of thermal energy and mass. However, the viscosity of mantle-relevant materials, such as MgO, at relevant pressures (>120 GPa) are not well constrained. The objective of this work was to develop a computational platform to simulate novel experiments aiming to measure the viscosity of MgO at high pressures. Experiments performed by our collaborators at Johns Hopkins University and Lawrence Livermore National Laboratory use the OMEGA EP laser facility to shock a corrugated MgO interface to 170 GPa, with resulting velocity evolution governed by the viscous Richtmyer-Meshkov instability. We used an in-house hydrocode to simulate this process and thus provide a bound on viscosity by comparing our simulations results to these experiments, as well as to examine the physical processes at play. We simulated the experiments with different values of MgO viscosity (from inviscid to 10,000 Pa∙s) while taking into account the unsteady laser pulse, the material's equation of state, and the rate-dependent constitutive relation for MgO, and the materials' equations of state. Our results suggest that MgO at these conditions has a viscosity within an order of magnitude of 5000 Pa∙s.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

CFD modeling of high-flux plate-and-frame membrane modules for industrial carbon capture

In this work, we study the application of membrane-based separation systems for carbon capture, considering plate-and-frame membrane modules. The successful deployment of membrane CO2 capture system relies on high-performing membranes as well as effective membrane modules that can fully exploit the developed membranes. A plate-and-frame membrane module is especially attractive for CO2 capture from industrial flue gas due to its lower pressure drop compared to its counterparts such as spiral wound modules and hollow fiber modules. To design better plate-and-frame modules, we investigate their basic unit - a single membrane stack through a combination of computational modeling and experimental investigations. The modeling approach is based on Computational Fluid Dynamics (CFD) to represent a multiphysics problem, including the fluid flow and diffusion processes within a membrane module. We use experimental data collected under different operating conditions to validate the CFD model. Numerical results suggest a good agreement between experiments and model outputs for the CO2 recovery, CO2 mole fraction in the retentate and permeate, and stage-cut. The CFD model is able to predict accurately the flow behavior, providing valuable insights on the effects of fluid dynamics on mass transfer of CO2. We also carry out a sensitivity analysis to identify the effect of key parameters on the CO2 recovery and the CO2 purity of the outlet streams.

Dosso, Cheick↗
DOE OSTI2025

A computational investigation of high-flux, plate-and-frame membrane modules for industrial carbon capture

In this work, we study the application of membrane-based separation systems for carbon capture, considering plate-and-frame membrane modules. The successful deployment of membrane CO 2 capture system relies on high-performing membranes as well as effective membrane modules that can fully exploit the developed membranes. A plate-and-frame membrane module is especially attractive for CO 2 capture from industrial flue gas due to its lower pressure drop compared to its counterparts such as spiral wound modules and hollow fiber modules. To design better plate-and-frame modules, we investigate their basic unit - a single membrane stack through a combination of computational modeling and experimental investigations. The modeling approach is based on Computational Fluid Dynamics (CFD) to represent a multiphysics problem, including the fluid flow and diffusion processes within a membrane module. We use experimental data collected under different operating conditions to validate the CFD model. Numerical results suggest a good agreement between experiments and model outputs for the CO 2 recovery, CO 2 mole fraction in the retentate and permeate, and stage-cut. The CFD model is able to predict accurately the flow behavior, providing valuable insights on the effects of fluid dynamics on mass transfer of CO 2 . We also carry out a sensitivity analysis to identify the effect of key parameters on the CO 2 recovery and the CO 2 purity of the outlet streams.

CFD simulation↗
DOE OSTI2023

NREL 25-cm2 High-Pressure Low-Temperature Electrolysis Cell Hardware (Open Source)

This data resource describes an open-source cell hardware that enables low temperature electrolysis (LTE) testing at elevated pressures. Existing commercial options have several downsides when it comes to R&D testing. They are often not designed for repeated reassembly, may not be able to accommodate porous transport layers with different thicknesses, and do not give state-of-the-art performance. Therefore, this hardware was developed specifically with LTE R&D in mind and its design is being made available to the global LTE community. This work was planned and funded by the U.S. Department of Energy's H2NEW consortium (https://h2new.energy.gov/). The hardware design package (.zip file) details the drawings, auxiliary materials, and procedures required to fabricate, assemble, and operate the National Renewable Energy Laboratory's (NREL's) high-pressure low-temperature electrolysis cells. While the hardware itself—end plates, current collectors, flow fields, bolts and washers, tube fittings—is always the same, the assembly and operating procedures may change depending on the active materials being tested, especially for the membrane. Material-specific assembly and operating procedures will be posted to the H2NEW website as they are developed and validated. Disclaimer: The documents and drawings included in this download package describe a design for a low temperature electrolysis hardware that is intended to comply with leak testing according to ASME B31.1. Safe operation at ambient and elevated pressures is the sole responsibility of the end user, which should be evaluated on a case-by-case basis for each individual cell. Factors affecting the sealing capability may depend on, for example, machining quality, cell assembly components, operating conditions, and operating history. Operation at pressure should only be performed on qualified test stands by qualified operators. NREL/ALLIANCE FOR SUSTAINABLE ENERGY, LLC/DOE DISCLAIM ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND MAKES NO WARRANTY AS TO THE ACCURACY, COMPLETENESS, OR USEFULNESS OF ANY INFORMATION PROVIDED HEREIN. USE OF THIS PACKAGE IS AT THE USER’S OWN RISK.

08 HYDROGEN↗
DOE OSTI2023

Stress characterization for friction-stir-welded electric vehicle battery trays with application of neutron diffraction

The battery tray is an essential component that protects and controls battery-cell temperatures in electric and plug-in hybrid vehicles. The functional stress limit of the battery tray heavily depends on the residual stress acquired from the manufacturing process. Consequently, exceeding the stress limit of the battery tray during operation could compromise the battery-cell banks and may risk the vehicle's safety. Hence, understanding residual stress formation is vital for design and safety concerns. Here, in the current study, AA 6061-plates were friction stir welded to an A365 high-pressure die-cast battery tray to create sealed coolant channels in the battery tray. However, this multi-material lap friction stir weld introduces residual stress into the battery tray, resulting in distortion. This distortion was mitigated using burnishing or coining operations, though straightening the battery tray had initially unknown effects on the residual stress. Therefore, neutron diffraction was utilized to characterize residual stresses after straightening. The results indicate that the friction stir welding (FSW) operation generated residual stresses exceeding the yield strength of the material, consequently deforming the battery tray by ±3 mm from the pre-weld geometry. The burnishing operation reduced the residual stresses below the material's yield strength while restoring the tray to within ±0.75 mm of the pre-weld geometry. Similarly, the coining operation restored the battery tray to within ±0.75 mm of the pre-weld geometry, however, increasing the number of locations where the residual stress exceeds the yield strength of the material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The role of micro-inertia on the shock structure in porous metals

The behavior of porous materials under shock loading is a multi-scale problem bridging orders of magnitude across the macroscale geometry and the microscale pores. Under static loading, this problem is well understood, relating mechanisms of pore closure and crushing to the equivalent macroscale models. The dynamic response of porous solids under shock loading is related to the effects of viscoplasticity and micro-acceleration fields around the void boundaries. The significance of the micro-inertia effects in modeling the dynamic behavior of porous materials remains an open question. In this work, an experimental investigation on closed-cell porous aluminum with small porosity provides the evidence for the first time of micro-inertia’s fundamental role in describing the shock structure in these materials. Materials with different levels of porosity were manufactured using a modified process of additive manufacturing to achieve a mean pore size below 50$\mu$m. Plate impact experiments on porous aluminum samples were conducted at pressures in the range of 2 to 11 GPa. The structure of the steady shock was characterized as a function of porosity and shown to validate behavior revealed by an analytical approach (Czarnota et al. [J. Mech. Phys. Solids 107 (2017)]), highlighting the fundamental role of micro-inertia effects in such cases.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fast strength model characterization using Bayesian statistics

A variety of flow stress models exist with new models constantly being developed. These models aim to approximate the strength of materials in a variety of regimes from quasistatic loading through shock scenarios. All models contain an array of parameters which need to be tuned to the material under study. Some models perform well under limited conditions, requiring adjustment of the parameters when venturing outside of those predefined ranges. Other models perform well over a wide range of conditions with a set of parameters, but may be outperformed by other models optimized on a tighter range of conditions. Recent research by Los Alamos demonstrated the ability to optimize the Johnson Cook (JC) model using a set of 3 plate-impact experiments on Aluminum. They utilized Bayesian statistics and emulation to determine optimal parameters for the model with a quantification of parameter uncertainty. We present an extension of this capability to incorporate velocimetry from plate-impact tests, stress-strain data from split Hopkinson pressure bar and quasistatic compression tests, plus profiles from Taylor cylinders in a unified fashion. Statistically robust comparisons of the performance and uncertainty of different realizations of the JC flow stress model were carried out based on calibration to several possible combinations of these three different experiment types.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Hugoniot states and optical response of soda lime glass shock compressed to 120 GPa

In contrast to relatively pure silica glass (fused silica-FS), commercial silica-rich glasses contain significant fractions of additional oxide components. In particular, soda-lime glass (SLG) consists of approximately 71% SiO 2 by weight, which raises the question: what is the effect of additional cations on the shock compression response of silica-rich glasses? To address this concern, plate impact experiments were conducted to determine the high-pressure Hugoniot states for shocked SLG (37 to 120 GPa) and compared with recently reported results on FS. Using laser interferometry, particle velocity profiles were measured at the impact surface and the SLG/LiF window interface. In all experiments, the transmitted profiles show a single shock wave, with no features indicative of a phase transformation. The Hugoniot states determined from the wave profiles are described well using a linear shock velocity–particle velocity relation. Interferometry measurements (using 1550-nm wavelength laser) at the impact surface show that SLG is transparent when shocked to 55 GPa, transparent for tens of nanoseconds after impact between 55 and 81 GPa, and opaque beyond 81 GPa. From impact surface measurements, a linear relationship between the apparent and true particle velocity was observed, resulting in a linear relationship between the refractive index (at 1550 nm) and density. At 120 GPa, the SLG density is nearly twice its ambient value, indicating that SLG can achieve highly dense amorphous states. When compared to FS, shocked SLG is much less compressible and likely does not transform to a crystalline phase. A plausible explanation for this difference is indicated.

58 GEOSCIENCES↗
DOE OSTI2026

Additional Data Focused on Phase 1 Geared Toward Computational Fluid Dynamics (CFD) validation

A new validation campaign was developed within the Offshore Code Comparison Collaboration, Continued, with Correlation and unCertainty (OC6) to better understand the complex interactions between components of a floating wind system (e.g., columns, pontoons, etc.) in a more generic sense, and to validate modeling approaches for a variety of floating designs. A set of cylinders based on the Offshore Code Comparison Collaboration Continuation (OC4)-DeepCwind semidesign were tested under wave loading, both individually and in different combinations (including the attachment of heave plates of different sizes). The cylinders were held rigid, and pressure sensors were used to measure the distributed loading on the structures, while load cells measured the total integrated hydrodynamic loads.

17 WIND ENERGY↗
DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Advancing Li-plating detection: Motivating a multi-signal correlation approach

Facilitating fast charging in lithium-ion batteries (LiBs) is often linked to Li-plating, which harms performance, longevity, and safety. Early detection of Li-plating is essential for rapid technological development and for preventing performance deterioration and ensuring safety during operation. Fast and real-time detection, using commonly collected measurements like voltage (V), current (I), temperature (T), and pressure (P), is highly desirable. Existing standalone methods relying on electrochemical and mechanical signatures, using half, smaller, or specially designed cells often operated at lower temperatures, fail to account for real-world fast-charging conditions. These signatures may also have inherent unreliability in aged LiBs, a phenomenon currently not-well understood. All these uncertainties have complicated practical implementation of a robust Li-plating detection technique. This study, through multiple case studies involving real-world fast-charging conditions using automotive-grade 11.6 Ah LiBs, shows that many single signal-based diagnostic techniques may be inadequate to detect Li-plating. Among various signatures, end-of-charge rest pressure, differential pressure-sensing, and end-of-charge rest voltage were identified as particularly useful in detecting Li-plating. Furthermore, A multi-signal-based detection technique is shown to be more robust in detecting Li-plating. Using both fresh and aged cells, the results and analysis highlight how detection capabilities are influenced by various factors, including battery design, size, charging speed, operating temperature, and degradation level. Adopting such a multi-signal Li-plating detection approach may be instrumental in the rapid development of battery technology in laboratories, as well as ensuring the enhanced safety of next-generation LiBs in real-world fast-charging applications.

25 ENERGY STORAGE↗