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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 OSTI2020

Detachment in Fusion Plasmas with Symmetry Breaking Magnetic Perturbation Fields

Power exhaust from the bulk plasma is significantly altered by symmetry breaking magnetic perturbation fields, because these create direct connections (perturbed field lines) from the confined high temperature plasma to solid surfaces. Additionally, the same amount of power is distributed among those new exhaust channels as for a symmetric magnetic configuration, which reduces the local upstream heat flux flowing down the perturbed field lines, thereby making access to detachment easier (i.e., at lower upstream density) for the divertor plasma near the location corresponding to the symmetric magnetic separatrix. However, the divertor plasma regions with connection to the bulk plasma are extended nonaxisymmetrically further outside, where significant heat loads occur, unlike in the symmetric configuration. The temperature remains high at those locations, which reduces the divertor plasma dissipation capacity, making the mitigation of heat loads more difficult to achieve.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Electron Paramagentic Resonance Investigation of Mechanism of Light- and Elevated-Temperature-Induced Degradation in Ga-doped Cz Si

We report on the electron paramagnetic resonance (EPR) spectra recorded at 6 K for Ga-doped Czochralski (Cz) Si in the initial stages of light- and elevated-temperature-induced degradation (LeTID). We show that the narrow-range EPR spectrum depends on the duration of simultaneous heat and light exposure. After prolonged LeTID, the EPR intensity increases at ~334 mT. The EPR signature at ~334 mT is characteristic of Si dangling bonds, and the increase in the dangling bond density can be attributed to the bulk and not the surface. Additionally, we show that the inverse of the minority carrier lifetime in Ga-doped Cz Si samples, measured by quasi-steady-state photoconductance (QSSPC) decay, correlates with the increase in the intensity of the Si dangling bond signal measured by EPR. Based on these observations, we put forth a hypothesis connecting H to LeTID and the corresponding defect structure.

Cz Si↗
DOE OSTI2025

NFE-24-10417: Durability and Life-time Energy Performance Enhancement of Vapor Compression Systems

This project investigated the use of a Centrifugal Particle Separation (CPS) system to improve the durability and operational reliability of outdoor heat exchangers in vapor-compression based heating, ventilation, air conditioning, and refrigeration (HVACR) systems. The developed method introduced a novel dust and fouling mitigation approach by integrating an ambient air pre-cleaner that employs centrifugal forces to remove particulate matter from incoming air before it reaches the heat exchanger. By reducing the accumulation of dust and debris on coil surfaces, the CPS system aims to lower maintenance requirements and extend equipment lifespan. The project specifically involves coupling a centrifugal air pre-cleaner with a single-zone ductless mini-split system and evaluating its effectiveness in maintaining cleaner coil surfaces. Additionally, the study examined the impact of CPS integration on system energy performance. Through controlled experimental testing and performance monitoring, this work seeks to validate CPS-based air pre-cleaning as a practical, efficient solution for mitigating outdoor coil dust accumulation and fouling in both residential and commercial HVACR applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Exploiting the Properties of Non-Wood Feedstocks to Produce Tailorable Lignin-Containing Cellulose Nanofibers

Lignin-containing cellulose nanofibrils (LCNFs) are mainly produced commercially from treated wood pulp, which can decrease some of the carbon-negative benefits of utilizing biomass feedstock. In this work, LCNFs are prepared from non-wood feedstocks, including agricultural residues such as hemp, wheat straw, and flax. These feedstocks allowed for the preparation of LCNFs with a variety of properties, including tailored hydrophobicity. The feedstocks and their subsequent LCNFs are extensively characterized to determine the roles that feedstocks play on the morphology and properties of their resultant LCNFs. The LCNFs were then incorporated into paper handsheets to study their usefulness in papermaking applications, which indicated good potential for the use of wheat straw LCNFs as a surface additive to improve the oil resistance coating.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Flare Statistics for Young Stars from a Convolutional Neural Network Analysis of TESS Data

All-sky photometric time-series missions have allowed for the monitoring of thousands of young (t age < 800 Myr) stars in order to understand the evolution of stellar activity. In this work, we developed a convolutional neural network (CNN), stella, specifically trained to find flares in Transiting Exoplanet Survey Satellite (TESS) short-cadence data. We applied the network to 3200 young stars in order to evaluate flare rates as a function of age and spectral type. The CNN takes a few seconds to identify flares on a single light curve. We also measured rotation periods for 1500 of our targets and find that flares of all amplitudes are present across all spot phases, suggesting high spot coverage across the entire surface. Additionally, flare rates and amplitudes decrease for stars t age > 50 Myr across all temperatures T eff ≥ 4000 K, while stars from 2300 ≤ T eff < 4000 K show no evolution across 800 Myr. Stars of T eff ≤ 4000 K also show higher flare rates and amplitudes across all ages. We investigate the effects of high flare rates on photoevaporative atmospheric mass loss for young planets. In the presence of flares, planets lose 4%–7% more atmosphere over the first 1 Gyr. stella is an open-source Python toolkit hosted on GitHub and PyPI.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Direct analysis of cotton swipes for uranium and plutonium isotopic determination by microextraction-ICP-MS

The determination of uranium and plutonium isotopic abundance on environmental samples collected by International Atomic Energy Agency (IAEA) inspectors is vital for the detection of undeclared nuclear activities and material under the international nuclear safeguards regime. Current analytical protocols require time-consuming sample preparation steps prior to subsequent measurement by inorganic mass spectrometry (MS). Recent efforts from this laboratory have focused on developing sample preparation methods for faster analysis, potentially allowing higher sample throughput[1]. Alternative methods including microextraction sampling in conjunction with inductively coupled plasma-mass spectrometry (ICP-MS) have been recently explored. This methodology, microextraction-ICP-MS, was developed such that uranium and plutonium could be extracted from the swipe surface and directed into the ICP-MS for an in-situ measurement, eliminating the need for swipe ashing and digestion. A commercial off-the-shelf microextraction system was customized with an automated movable XY stage that can be programmed to save sampling locations, allowing for automated rapid sampling of swipe surfaces. Additional efforts have focused on the utilization of collision cell technology to the microextraction ICP-MS method. This would eliminate the need for lengthy column chemistry procedures to purify separated uranium and plutonium fractions before analysis. Here, the extracted U/Pu analyte is measured by reacting the uranium ions with CO2 in the collision cell of an ICP-MS, shifting the uranium to UO+, which will not interfere with the plutonium isotopic determination. The developed method utilizing collision cell – ICP-MS technology has demonstrated the ability to measure plutonium isotope ratios in the presence of high uranium concentration on the transient signal from the microextraction system utilizing certified reference materials from JRC-Geel and the New Brunswick Laboratory Program Office.

Bradley, Veronica↗
DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗
DOE OSTI2022

Enhancing Surface Finish of Additively Manufactured 316L Stainless Steel with Pulse/Pulse Reverse Electropolishing

To improve the reliable integration of additively manufactured (AM) metal components, there is an urgent need for surface finishing methods capable of processing rough, “as-printed” surfaces. Here, we present a new and scalable electropolishing (EP) technique for use on AM 316L stainless steel (SS) that is capable of achieving a surface roughness equivalent to a machined finish, with arithmetic mean heights (S a ) as low as 1.0 µm. This technique utilizes the sequential application of a new, NaCl/H 2 O pulse/pulse reverse (P/PR) EP step along with a conventional DC (direct current) EP step, where P/PR expands the capability of EP by removing roughness features > 1 µm, which has been previously unattainable with DC EP alone without substantial material removal. This is achieved by independently varying pulse parameters, such as pulse width and height, allowing more control over electrodynamic processes at the part-electrolyte interface. Additionally, P/PR EP resulted in higher smoothing efficiency, where a higher degree of smoothing was achieved with less material removal when compared with conventional DC EP alone. This minimizes unwanted change in geometry from excessive metal dissolution.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Review of internal and external surface finishing technologies for additively manufactured metallic alloys components and new frontiers

Surface finishing in additive manufacturing (AM) is a technological bottleneck. The field of surface finishing of AM parts is vast because it not only focuses on roughness reduction in the hard-to-access internal surfaces but also includes the scope of adding coatings and sensors. Even though metal AM component is reaching the density and bulk microstructure at par or even better than conventionally produced components, adverse impact of surface roughness and imperfections is becoming the major obstruction. It is observed that external and internal surface roughness of AM components is a high probability cause of many unavoidable issues such as corrosion, incorrect tolerance estimations during the build stage, and the fatigue failure of parts before the expected life cycle. At present, AM field mainly focuses on improving and enhancing the internal and external surface roughness to pass the stringent qualification requirements for actual applications. To address these challenges, researchers worldwide are conducting many experiments and developing different surface finishing techniques. This paper reviews the state-of-the-art knowledge and processes of different surface finishing technology that can be applied to AM metal components. This article mainly highlights several liquid-based surfaces finishing approaches to develop promising surface microstructures on interior and exterior surfaces as a micromachining tool. The future of making strong and self-monitoring AM component requires broadening of surface finishing field and including advanced topics such as coatings and adding sensor technology. We also discuss new frontiers and the scope of future work in the surface finishing field to bring attention to related concerns and possibilities associated with making smart and strong AM components for twenty-first-century integrated engineering systems.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Improve durability and surface quality of additively manufactured molds using carbon fiber prepreg

Hybrid tooling is an emerging concept introduced in the aerospace industries to reduce weight and cost of traditional tools. A hybrid tool features a skin, which provides desired surface quality, durability, and a low-density substrate to reduce the weight of the mold. The big area additive manufacturing (BAAM) technology permits rapid production of thermoplastic polymer intensive large-scale structures. The present study features a carbon fiber reinforced polyphenylene sulfide (CF-PPS) substrate fabricated using Oak Ridge National Laboratory's BAAM system. Carbon fiber-bismaleimide (CF-BMI) prepreg skin was then bonded to the BAAM tool through high-pressure autoclave molding. Process optimization was conducted to improve the bonding between CF-PPS and CF-BMI (transverse tensile strength increased from 0.54 to 4.8 MPa). Durability of the mold was demonstrated from fabricating seven (7) carbon fiber-Huntsman epoxy hand lay-up parts utilizing the mold.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Surface Preparation of Additively Manufactured 316H Stainless Steel for Molten Salt Applications

Additive manufacturing (AM) has the potential to revolutionize the manufacturing process and speed up deployment of advance nuclear reactors. However, more information is needed on preparing AM materials for extreme reactor environments to qualify AM materials for nuclear applications. This project studies the surface preparation of AM 316H stainless steel using acid pickling and reports a successful procedure for descaling heat-treated AM material.

316H Stainless Steel↗
DOE OSTI2022

Pit Stability Predictions of Additively Manufactured SS316 Surfaces Using Finite Element Analysis

Stainless steels are susceptible to localized forms of corrosion attack, such as pitting. The size and lifetime of a nucleated pit can vary, depending on a critical potential or current density criterion, which determines if the pit repassivates or continues growing. This work uses finite element method (FEM) modeling to compare the critical pit radii predicted by thermodynamic and kinetic repassivation criteria. Experimental electrochemical boundary conditions are used to capture the active pit kinetics. Geometric and environmental parameters, such as the pit shape and size (analogous to additively manufactured lack-of-fusion pores), solution concentration, and water layer thickness were considered to assess their impact on the pit repassivation criterion. The critical pit radius (the transition point from stable growth to repassivation) predicted for a hemispherical pit was larger when using the repassivation potential (E rp ) criteria, as opposed to the current density criteria (pit stability product). Including both the pit stability product and E rp into its calculations, the analytical maximum pit model predicted a critical radius two times more conservative than the FEA approach, under the conditions studied herein. The complex pits representing lack-of-fusion pores were shown to have minimal impact on the critical radius in atmospheric conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗
DOE OSTI2021

Development of an anti-clogging perforated plate atomizer for a zero liquid discharge humidification-dehumidification desalination system

An anti-clogging perforated plate atomizer is designed for high temperature and salinity applications in a novel solar-powered zero liquid discharge humidification-dehumidification desalination system (US Patent Application US62882953). Herein this paper presents a detailed discussion on its design, and operation. Experiments are performed on seven atomizers to study the effect of design, and operating parameters on spray cone angle, and average droplet diameter. Spray cone angle remains constant with change in air mass flux, and increases with increasing orifice diameter, and manifold diameter. It also increases initially with water mass flow rate, and manifold height, before attaining a constant value. Average droplet diameter increases with increasing water mass flow rate, and decreasing air mass flux, orifice diameter, and manifold diameter. Further, anti-clogging performance of the atomizer is tested with hypersaline water of 100,000 ppm total dissolved solid (NaCl) at elevated temperatures such as air at 175 °C and saline water at 45 °C. Results show no clogging for 2–13 h of operation. Near-complete suppression of atomizer clogging makes our new additively-manufactured perforated plate atomizer an ideal fit for high salinity, and zero liquid discharge humidification-dehumidification desalination systems. Additionally, its open-surface design allows additional surface modifications to further reduce clogging, and enhance self-cleaning characteristics.

47 OTHER INSTRUMENTATION↗