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DOE OSTI2019

Molten Salt Reactor Experiment (MSRE) Lay-Up - 19187

UCOR, an AECOM-led partnership with Jacobs, manages the cleanup of the 2,200-acre East Tennessee Technology Park for its client, the U.S. Department of Energy (DOE), in Oak Ridge, Tennessee. The site was contaminated with radioactive, hazardous and industrial wastes generated by more than 40 years of national defense and energy missions. 2019 is the 50. anniversary of the shutdown of the Molten Salt Reactor Experiment (MSRE). MSRE ran a brief four years in the 1960's but earned an enduring legacy as an innovative reactor technology concept which has enjoyed a renewal of global interest in the past several years. In 2018, it was given elevated status among advanced reactor programs within DoE's Nuclear Energy office. The MSRE was a graphite-moderated, liquid fueled reactor that operated from June 1965 through December 1969. Although it was shut down nearly 50 years ago, certain systems within the reactor have continued to operate to maintain the facility in a safe and stable condition until it can be demolished as part of the comprehensive cleanup of the Oak Ridge Reservation. These systems are composed of a complex network of pipes, valves, gauges and associated equipment that control air filtration and pressure buildup resulting from fluorine gas generated through radiolysis of the fluoride salt which once fueled the reactor. In 2016, an MSRE Engineering Evaluation Team was chartered to assess current facility conditions and develop recommendations to maintain the facility in a safe state until deactivation and demolition commences. Plans are now underway to 'lay up' the MSRE facility until deactivation and demolition can occur. The proposed MSRE Facility Layup will minimize maintenance costs, reduce personnel risk of injury and exposure, provide reliable electric service to the facility and require zero personnel occupancy at MSRE. In the proposed layup approach a new source of electrical power to required loads will be routed through the facility, and new gas processing and ventilation systems will be installed that will be optimized for safe processing of the constituent hazardous gasses that exist in the legacy vessels at MSRE. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Energy storage planning for enhanced resilience of power systems against wildfires and heatwaves

Extreme weather events pose significant risks to power grid stability due to their severe consequences and potential for widespread failures. Energy storage systems hold great potential for enhancing grid resilience against such events by providing reliable power during peak demand periods. However, accurately quantifying the size, location, and investment costs of new energy storage assets is a complex task, as energy storage planning decisions depend on the investment choices of other generation technologies and the integration of new transmission projects. Here, this paper presents a novel capacity expansion planning framework that simultaneously optimizes investments in energy storage, generation, and transmission, determining their optimal size, location, and type, while incorporating extreme weather events into long-term planning. More specifically, our stress-event-informed planning framework integrates the impact of heatwaves and wildfires into the planning process, identifying least-cost investment solutions that comply with policy goals and enhance grid resilience. The proposed framework employs machine-learning-based modeling to project heatwave-induced loads and performance-based risk assessment to evaluate wildfire-driven transmission line derates. Using industry-standard datasets to accurately represent the transmission topology of the Western Interconnection (WI) system, the proposed framework is applied to the WI 40-zone system, with investment decisions reported for the years 2030, 2035, and 2040. Simulation results reveal that with just a 10% increase in investment costs, resilience against extreme events can be significantly improved, with investment decisions heavily favoring energy storage, particularly 4-hour energy storage systems.

25 ENERGY STORAGE↗

DOE OSTI2021

A Component-Sizing Methodology for a Hybrid Electric Vehicle Using an Optimization Algorithm

Many leading companies in the automotive industry have been putting tremendous effort into developing new powertrains and technologies to make their products more energy efficient. Evaluating the fuel economy benefit of a new technology in specific powertrain systems is straightforward; and, in an early concept phase, obtaining a projection of energy efficiency benefits from new technologies is extremely useful. However, when carmakers consider new technology or powertrain configurations, they must deal with a trade-off problem involving factors such as energy efficiency and performance, because of the complexities of sizing a vehicle’s powertrain components, which directly affect its energy efficiency and dynamic performance. As powertrains of modern vehicles become more complicated, even more effort is required to design the size of each component. This study presents a component-sizing process based on the forward-looking vehicle simulator “Autonomie” and the optimization algorithm “POUNDERS”; the supervisory control strategy based on Pontryagin’s Minimum Principle (PMP) assures sufficient computational system efficiency. We tested the process by applying it to a single power-split hybrid electric vehicle to determine optimal values of gear ratios and each component size, where we defined the optimization problem as minimizing energy consumption when the vehicle’s dynamic performance is given as a performance constraint. The suggested sizing process will be helpful in determining optimal component sizes for vehicle powertrain to maximize fuel efficiency while dynamic performance is satisfied. Indeed, this process does not require the engineer’s intuition or rules based on heuristics required in the rule-based process.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2015

OLED Fundamentals: Materials, Devices, and Processing of Organic Light-Emitting Diodes

What is an organic light emitting diode (OLED)? Why should we care? What are they made of? How are they made? What are the challenges in seeing these devices enter the marketplace in various applications? These are the questions we hope to answer in this book, at a level suitable for knowledgeable non-experts, graduate students and scientists and engineers working in the field who want to understand the broader context of their work. At the most basic level, an OLED is a promising new technology composed of some organic material sandwiched between two electrodes. When current is passed through the device, light is emitted. The stack of layers can be very thin and has many variations, including flexible and/or transparent. The organic material can be polymeric or composed small molecules, and may include inorganic components. The electrodes may consist of metals, metal oxides, carbon nanomaterials, or other species, though of course for light to be emitted, one electrode must be transparent. OLEDs may be fabricated on glass, metal foils, or polymer sheets (though polymeric substrates must be modified to protect the organic material from moisture or oxygen). In any event, the organic material must be protected from moisture during storage and operation. A control circuit, the exact nature of which depends on the application, drives the OLED. Nevertheless, the control circuit should have very stable current control to generate uniform light emission. OLEDs can be designed to emit a single color of light, white light, or even tunable colors. The devices can be switched on and off very rapidly, which makes them suitable for displays or for general lighting. Given the amazing complexity of the technical and design challenges for practical OLED applications, it is not surprising that applications are still somewhat limited. Although organic electroluminescence is more than 50 years old, the modern OLED field is really only about half that age – with the first high-efficiency OLED demonstrated in 1987. Thus, we expect to see exciting advances in the science, technology and commercialization in the coming years. We hope that this book helps to advance the field in some small way. Contributors to this monograph are experts from top academic institutions, industry and national laboratories who provide comprehensive and up-to-date coverage of the rapidly evolving field of OLEDs. Furthermore, this monograph collects in one place, for the first time, key topics across the field of OLEDs, from fundamental chemistry and physics, to practical materials science and engineering topics, to aspects of design and manufacturing. The monograph synthesizes and puts into context information scattered throughout the literature for easy review in one book. The scope of the monograph reflects the necessity to focus on new technological challenges brought about by the transition to manufacturing. In the Section 1, all materials of construction of the OLED device are covered, from substrate to encapsulation. In Section 2, for the first time, additional challenges in devices and processing are addressed. This book is geared towards a broad audience, including materials scientists, device physicists, synthetic chemists and electrical engineers. Furthermore, this book makes a great introduction to scientists in industry and academia, as well as graduate students interested in applied aspects of photophysics and electrochemistry in organic thin films. This book is a comprehensive source for OLED R&D professionals from all backgrounds and institutions.

OLED↗

DOE OSTI2018

Functional and structural characterization of a β-glucosidase involved in saponin metabolism from intestinal bacteria

Highlights: • Bifidobacterium longum are involved in the metabolism of saponins. • BlBG3 shows higher efficiency to saponins than known bacterial β-glucosidases. • First structure of β-glucosidase from intestinal bacteria to hydrolyze saponins. • A special binding pocket differs to other structural available GH3 β-glucosidases. • Molecular docking revealed the binding interactions of substrate with BlBG3. Saponins are natural glycosides widely used in medicine and the food industry. Although saponin metabolism in human is dependent on intestinal microbes, few involving bacteria enzymes have been identified. We cloned BlBG3, a GH3 β-glucosidase from Bifidobacterium longum, from human stool. We found that BlBG3 catalyzes the hydrolysis of glycoside furostanol and ginsenoside Rb1 at higher efficiency than other microbial β-glucosidases. Structural analysis of BlBG3 in complex with d-glucose revealed its three unique loops, which form a deep pocket and participate in substrate binding. To understand how substrate is bound to the pocket, molecular docking was performed and the binding interactions of protobioside with BlBG3 were revealed. Mutational study suggested that R484 and H642 are critical for enzymatic activity. Our study presents the first structural and functional analysis of a saponin-processing enzyme from human microbiota.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

A CPS Based Optimal Operational Control System for Fused Magnesium Furnace

Fused magnesia smelting for fused magnesium furnace (FMF) is an energy intensive process with high temperature and comprehensive complexities. Its operational index namely energy consumption per ton (ECPT) is defined as the consumed electrical energy per ton of acceptable quality and is difficult to measure online. Moreover, the dynamics of ECPT cannot be precisely modelled mathematically. The model parameters of the three-phase currents of the electrodes such as the molten pool level, its variation rate and resistance are uncertain and nonlinear functions of the changes in both the smelting process and the raw materials composition. In this paper, an integrated optimal operational control algorithm proposed is composed of a current set-point control, a current switching control and a self-optimized tuning mechanism. The tight conjoining of and coordination between the computational resources including the integrated optimal operational control, embedded software, industrial cloud, wireless communication and the physical resources of FMF constitutes a cyber-physical system (CPS) based embedded optimal operational control system. Successful application of this system has been made for a production line with ten fused magnesium furnaces in a factory in China, leading to a significant reduced ECPT.

Cyber-Physical Systems↗

DOE OSTI2019

Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems

Metallic alloy bond coats are used as an interlayer to promote adhesion of ceramic Thermal Barrier Coatings (TBCs) to the superalloy substrates. These bond coats can be applied through a variety of processing means such as Air Plasma Spray (APS), High-Velocity Oxy Fuel spray (HVOF), and Vacuum Plasma Spray (VPS). While widely adopted in the industry, some uncertainties remain as to the specific microstructural attributes which are influenced by the processing routes and their implications on durability. This paper seeks to elucidate these subtleties between bond coat deposition processing routes through an integrated study of processing to connect to furnace cycle durability on a single bond coat chemistry of NiCoCrAlYHfSi. A standard porous APS TBC top coating based on yttria stabilized zirconia (7YSZ) was consistently applied on these distinct bond coats and tested for durability in cyclic furnace testing at 1100 °C. The results point to substantial differences in durability which are not readily explained only by the variances in coating roughness. Detailed assessment of deposited bond coat properties (modulus, thermal expansion, chemistry) provided some explanation relative to durability. Here, the results suggest a complex interplay among roughness, compliance, aluminum diffusion pathway, and thermal expansion mismatch. Photo-stimulated luminescence piezospectroscopy (PLPS) provided additional insights enabling a comprehensive assessment of processing-performance linkages.

36 MATERIALS SCIENCE↗

DOE OSTI2023

An Efficient Reactive Force Field without Explicit Coordination Dependence for Studying Caustic Aluminum Chemistry

Reactive force fields (RFFs) are an expedient approach to sample chemical reaction paths in complex systems, relative to density functional theory. However, there is continued need to improve efficiencies, specifically in systems that have slow transverse degrees of freedom, as in highly viscous and superconcentrated solutions. Here, we present an RFF that is differentiated from current models (e.g., ReaxFF) by omitting explicit dependence on the atom coordination and employing a small parameter set based on Lennard-Jones, Gaussian, and Stillinger–Weber potentials. In this study, the model was parametrized from AIMD simulation data and is used to model aluminate reactivity in sodium hydroxide solutions with extensive validation against experimental radial distribution functions, computed free energy profiles for oligomerization, and formation energies. In conclusion, the model enables simulation of early stage Al(OH) 3 nucleation which has significant relevance to industrial processing of aluminum and has a computational cost that is reduced by 1 order of magnitude relative to ReaxFF.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Probing polymer crystallization at processing-relevant cooling rates with synchrotron radiation

Processing of polymeric materials to produce any kind of goods, from films to complex objects, involves application of flow fields on the polymer melt, accompanied or followed by its rapid cooling. Typically, polymers solidify at cooling rates which span over a wide range, from a few to hundreds of °C/s. A novel method to probe polymer crystallization at processing-relevant cooling rates is proposed. Using a custom-built quenching device, thin polymer films are ballistically cooled from the melt at rates between approximately 10 and 200 °C/s. Thanks to highly brilliant synchrotron radiation and to state-of-the-art X-ray detectors, the crystallization process is followed in real-time, recording about 20 wide angle X-ray diffraction patterns per second while monitoring the instantaneous sample temperature. The method is applied to a series of industrially relevant polymers, such as isotactic polypropylene, its copolymers and virgin and nucleated polyamide-6. Their crystallization behaviour during rapid cooling is discussed, with particular attention to the occurrence of polymorphism, which deeply impact material’s properties.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2017

Hydrogen Energy California (Final Scientific and Technical Report)

Hydrogen Energy California ("HECA") is an Integrated Gasification Combined-Cycle (IGCC) “polygeneration” project. The Project gasifies a 75 percent coal and 25 percent petroleum coke (petcoke) fuel blend to produce synthesis gas (syngas). Syngas produced via gasification is purified to hydrogen-rich fuel, which is used to generate low-carbon baseload electricity in a Combined Cycle Power Block, low-carbon nitrogen-based products in an integrated manufacturing Complex, and carbon dioxide (CO 2 ) for use in enhanced oil recovery (EOR). The power and products produced by HECA have a lower carbon footprint compared to power and products produced from more traditional fossil fuel facilities. This low-carbon footprint is achieved by capturing more than 90 percent of the CO 2 in the production of the hydrogen fuel and transporting it for use in EOR, which results in simultaneous sequestration (storage) of the CO 2 in a secure geologic formation in the adjacent Elk Hills Oil Field (EHOF), a hydrocarbon producing area. Highlights of HECA as conceived during the execution of FEED are as follows: The Project is designed to operate on a fuel blend consisting of 75 percent western subbituminous coal and 25 percent California petcoke based on thermal input to the gasifier on a higher heating value (HHV) basis; The feedstocks are gasified to produce syngas that is further processed and cleaned to produce hydrogen-rich fuel; More than 90 percent of the carbon in the raw syngas is captured in a high-purity CO 2 stream during steady-state operation; High purity CO 2 is compressed and transported by pipeline to the EHOF for injection into deep underground hydrocarbon reservoirs for CO 2 EOR; The Combined Cycle Power Block produces over 420 megawatts (MW) of gross power, which yields during periods of maximum power production over 270 MW of low-carbon baseload electricity to the grid; An integrated Manufacturing Complex produces approximately 1 million tons per year of low-carbon nitrogen-based products, including urea, urea ammonium nitrate (UAN), and anhydrous ammonia, to be used in agricultural, transportation, and industrial applications.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2024

Direct HCN synthesis via plasma-assisted conversion of methane and nitrogen

Hydrogen cyanide (HCN) is synthesized from ammonia (NH 3 ) and methane (CH 4 ) at ~1200°C over a Pt catalyst. Ammonia synthesis entails several complex, highly emitting processes. Plasma-assisted HCN synthesis directly from CH 4 and nitrogen (N 2 ) could be pivotal for on-demand HCN production. Here, we evaluate the potential of dielectric barrier discharge (DBD) N 2 /CH 4 plasma for decentralized catalyst-free selective HCN production. We demonstrate a single-step conversion of methane and nitrogen to HCN with a 72% yield at <300°C. HCN is favored at low CH 4 concentrations with ethane (C 2 H 6 ) as the secondary product. We propose a first-principles microkinetic model with few electron impact reactions. The model accurately predicts primary product yields and elucidates that methyl radical (·CH 3 ) is a common intermediate in HCN and C 2 H 6 synthesis. Compared to current industrial processes, N 2 /CH 4 DBD plasma can achieve minimal CO 2 emissions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2006

More About the Tetrahedral Unstructured Software System

TetrUSS is a comprehensive suite of computational fluid dynamics (CFD) programs that won the Software of the Year award in 1996 and has found increasing use in government, academia, and industry for solving realistic flow problems (especially in aerodynamics and aeroelastics of aircraft having complex shapes). TetrUSS includes not only programs for solving basic equations of flow but also programs that afford capabilities for efficient generation and utilization of computational grids and for graphical representation of computed flows (see figure). The 2004 version of the Tetrahedral Unstructured Software System (TetrUSS), which is one of two software systems reported in "NASA s 2004 Software of the Year," NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 18, has been improved greatly since 1996. These improvements include (1) capabilities to simulate viscous flow by solving the Navier-Stokes equations on unstructured grids, (2) portability to personal computers from diverse manufacturers, (3) advanced models of turbulence, (4) a parallel-processing version of one of the unstructured-grid Navier-Stokes-equation-solving programs, and (5) advanced programs for generating unstructured grids.

Abdol-Hamid, Khaled S.↗

NASA NTRS2012

Damage Tolerance Assessment of Friction Pull Plug Welds

Friction stir welding is a solid state welding process developed and patented by The Welding Institute in Cambridge, England. Friction stir welding has been implemented in the aerospace industry in the fabrication of longitudinal welds in pressurized cryogenic propellant tanks. As the industry looks to implement friction stir welding in circumferential welds in pressurized cryogenic propellant tanks, techniques to close out the termination hole associated with retracting the pin tool are being evaluated. Friction pull plug welding is under development as a one means of closing out the termination hole. A friction pull plug weld placed in a friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite, plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size in the test or service environments. Test data relating residual strength capability to flaw size in two aluminum alloy friction plug weld configurations is presented.

McGill, Preston↗

DOE OSTI2020

Life Cycle Analysis of Greenhouse Gas Emissions for the Niagaran Reef Complex CO 2 -EOR Operations

The Midwest Regional Carbon Sequestration Partnership (MRCSP) was founded in 2003 as part of the U.S. Department of Energy’s (DOE’s) Regional Carbon Sequestration Partnership initiative. Since its founding, MRCSP has made significant strides toward making CCUS a viable option for states in the region. The public/private consortium, funded through the DOE Regional Carbon Sequestration Initiative, brings together nearly 40 industry partners and 10 states. Battelle, as the project lead, oversees research, development and operations and coordinates activities among the partners. The incremental, phased approach has built a valuable knowledge base for the industry and paved the way for commercial-scale adoption of CCUS technologies. From 2008 to 2020, MRCSP Phase III focused on the development of large-scale injection projects. This report is part of a series of reports prepared under the Midwestern Regional Carbon Sequestration Partnership (MRCSP) Phase III (Development Phase). These reports summarize and detail the findings of the work conducted under the Phase III project. A greenhouse gas emissions life cycle analysis (LCA) was completed for 22 years of carbon dioxide-enhanced oil recovery (CO 2 -EOR) operations at the Niagaran reef complex in the northern Michigan Basin based on research by the MRCSP. The objective of the greenhouse gas LCA was to account for the total greenhouse gas emissions generated through the CO 2 -EOR process. Methane produced from the 300 to 500 meter-deep Antrim shale has CO 2 content ranging from 5 percent to 30 percent. Therefore, the produced gas stream is gathered outside of Gaylord, Michigan, at the Chester 10 central gas processing plant, and run through an amine-based CO 2 separation process to remove the CO 2 so the methane can be sold to the market. The CO 2 is periodically dehydrated, compressed, and transported via pipeline for CO 2 -EOR in nearby 5,000- to 6,500-foot (1500-2000 m) deep carbonate Niagaran reefs. The produced mixture of oil, water, and CO 2 is separated at the Dover 36 oil processing facility. The processed CO 2 is recycled to the reefs for CO 2 -EOR in a closed loop system. During this process, a portion of the CO2 remains permanently stored in the reefs.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

ARM Aerial Facility (AAF) Merged Value-Added Product Report for Historical G-1 Field Campaigns

For 30 years, the U.S. Department of Energy (DOE) Office of Science supported an instrumented Grumman Gulfstream-1 (G-1) aircraft for atmospheric field campaigns. Data from the final decade of G-1 operations were archived by the Atmospheric Radiation Measurement (ARM) user facility Data Center (ADC) and made publicly available at no cost to all registered users. To ensure a consistent data format and to improve the accessibility of the ARM airborne data, an integrated data set was recently developed covering the final six years of G-1 operations (2013 to 2018). The integrated data set includes data collected from 236 flights (766.4 hours). Four of the seven field campaigns were based in the U.S. One campaign collected data from the wildfires in the U.S. Pacific Northwest and agricultural burns in the lower Mississippi River valley as part of the Biomass Burning Observation Project (BBOP) in 2013. In 2015, the ARM Cloud Aerosol Precipitation Experiment provided data on atmospheric rivers and associated aerosol-cloud interactions that produce heavy precipitation on the U.S. west coast during the early spring. Research data from Airborne Carbon Measurements-V (ACME-V), collected during the summer of 2015, gave scientists insight into trends and variability of trace gases in the atmosphere over the North Slope of Alaska to improve arctic climate models. In the early summer and autumn of 2016, the Holistic Interactions of Shallow Clouds, Aerosols, and Land-Ecosystems (HI-SCALE) campaign provided an extensive data set geared toward coupled processes that affect the life cycle of shallow clouds through the interaction among aerosol, cloud, land surface, and ecosystems. In 2014 (March and October), the airborne sampling moved outside of the U.S. to the city of Manaus in central Amazonia, Brazil, where residential and industrial emissions were extensively characterized by flights of the G-1. The GoAmazon2014/15 aircraft campaign data are being integrated with aquatic and terrestrial ecosystem measurements to quantify anthropogenic perturbations to a usually pristine tropical environment. Another international airborne mission was carried out in the Eastern North Atlantic region. The Aerosol and Cloud Experiments in the Eastern North Atlantic (ACE-ENA) campaign saw the G-1 aircraft fly from Terceira Island in the Azores during the summer of 2017 and the winter of 2018. The campaign studied both seasons to measure key aerosol and cloud processes under various meteorological and cloud conditions with different aerosol sources. Then the G-1 deployed to the Sierras de Córdoba range in central Argentina from October to November 2018 for the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) campaign to study orographic convective cloud interactions with their surrounding environment. These comprehensive datastreams provide much-needed insight into spatiotemporal variability of thermodynamic quantities, aerosol and cloud states, and properties for addressing essential science questions in Earth system process studies.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

ARM Aerial Facility (AAF) Merged Value-Added Product Report for Historical G-1 Field Campaigns

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗