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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 991 records · Page 55

Pellet to Part Manufacturing System for CNCs

Oak Ridge National Laboratory’s Manufacturing Demonstration Facility worked with Hybrid Manufacturing Technologies to develop a compact prototype composite additive manufacturing head that can effectively extrude injection molding pellets. The head interfaces with conventional CNC machine tools enabling rapid conversion of conventional machine tools to additive manufacturing tools. The intent was to enable wider adoption of Big Area Additive Manufacturing (BAAM) technology and combine BAAM technology with conventional machining systems.

42 ENGINEERING↗

Additive Manufacturing of Parts and Tooling in Robotic Systems

ORNL worked with Transcend Robotics, LLC to explore additive manufacturing of the two-piece compression body for their ARTI mobile robot platform. Extrusion compression molding was identified as an effective means of manufacturing these parts. ORNL consulted on modifications to the housing design to accommodate the selected manufacturing process. Parts were printed using ORNL's FDM machines for testing and evaluation of the design as a precursor to molding the parts. The assembly and evaluation of the parts proved favorable and minor design changes to improve assembly and performance were identified.The goal is to develop a light weight and rugged two-part robotic enclosure for an unmanned ground vehicle UGV) that will be used in search and rescue applications. The FDM parts fabricated by ORNL allowed Transcend Robotics to assemble a prototype robot and verify that the new parts will meet the performance requirements. ORNL fabricated enclosure parts out of ABS and Nylon 12 materials such that the design could be tested prior to fabricating tooling for compression molding of Nylon 6 with carbon fiber fill. The robot was performance tested and compared with the previous manufacturing techniques and found to have superior performance.

42 ENGINEERING↗

Standardized Procedure Content And Data Structure Based On Human Factors Requirements For Computer-Based Procedures

Most activities that involve human interaction with systems in a nuclear power plant are guided by procedures. Traditionally, the use of procedures has been a paper-based process that supports safe operation of the nuclear power industry. However, the nuclear industry is constantly trying to find ways to decrease the human error rate, especially the human errors associated with procedure use. Advances in digital technology make computer-based procedures (CBPs) a valid option that provides further enhancement of safety by improving human performance related to procedure use. The transition from paper-based procedures (PBPs) to CBPs creates a need for a computer-based procedure system (CBPS). A CBPS needs to have the ability to perform logical operations in order to adjust to the inputs received from either users or real time data from plant status databases. Without the ability for logical operations the procedure is just an electronic copy of the paper-based procedure. In order to provide the CBPS with the information it needs to display the procedure steps to the user, special care is needed in the format used to deliver all data and instructions to create the steps. The procedure should be broken down into basic elements and formatted in a standard method for the CBPS. One way to build the underlying data architecture is to use an Extensible Markup Language (XML) schema, which utilizes basic elements to build each step in the smart procedure. The attributes of each step will determine the type of functionality that the system will generate for that step. The CBPS will provide the context for the step to deliver referential information, request a decision, or accept input from the user. The XML schema needs to provide all data necessary for the system to accurately perform each step without the need for the procedure writer to reprogram the CBPS. The research team at the Idaho National Laboratory has developed a prototype CBPS for field workers as well as the underlying data structure for such CBPS. The objective of the research effort is to develop guidance on how to design both the user interface and the underlying schema. This paper will describe the result and insights gained from the research activities conducted to date.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Establishing a Cell-Free Vibrio natriegens Expression System

We report the fast growing bacterium Vibrio natriegens is an emerging microbial host for biotechnology. Harnessing its productive cellular components may offer a compelling platform for rapid protein production and prototyping of metabolic pathways or genetic circuits. Here, we report the development of a V. natriegens cell-free expression system. We devised a simplified crude extract preparation protocol and achieved >260 μg/mL of superfolder GFP in a small-scale batch reaction after 3 h. Culturing conditions, including growth media and cell density, significantly affect translation kinetics and protein yield of extracts. We observed maximal protein yield at incubation temperatures of 26 or 30 °C, and show improved yield by tuning ions crucial for ribosomal stability. Lastly, this work establishes an initial V. natriegens cell-free expression system, enables probing of V. natriegens biology, and will serve as a platform to accelerate metabolic engineering and synthetic biology applications.

59 BASIC BIOLOGICAL SCIENCES↗

Probing lithium mobility at a solid electrolyte surface

Abstract Solid-state electrolytes overcome many challenges of present-day lithium ion batteries, such as safety hazards and dendrite formation 1,2 . However, detailed understanding of the involved lithium dynamics is missing due to a lack of in operando measurements with chemical and interfacial specificity. Here we investigate a prototypical solid-state electrolyte using linear and nonlinear extreme-ultraviolet spectroscopies. Leveraging the surface sensitivity of extreme-ultraviolet-second-harmonic-generation spectroscopy, we obtained a direct spectral signature of surface lithium ions, showing a distinct blueshift relative to bulk absorption spectra. First-principles simulations attributed the shift to transitions from the lithium 1 s state to hybridized Li- s /Ti- d orbitals at the surface. Our calculations further suggest a reduction in lithium interfacial mobility due to suppressed low-frequency rattling modes, which is the fundamental origin of the large interfacial resistance in this material. Our findings pave the way for new optimization strategies to develop these electrochemical devices via interfacial engineering of lithium ions.

25 ENERGY STORAGE↗

Programmable exploration of magnetic states in Lieb-kagome interpolated lattices

We investigate a hybrid modeling framework in which a quantum annealer is used to simulate magnetic interactions in molecular qubit lattices inspired by experimentally realizable systems. Using phthalocyanine assemblies as a structurally constrained prototype, we model a continuous deformation from a Lieb to a kagome lattice, revealing frustration-driven disorder and magnetic field-induced reordering in the spin structure. Here, the goal is to show how a quantum annealer can operate as a physically instantiated, programmable platform to emulate experimentally relevant lattice deformations and produce observables in a manner analogous to an experimental measurement, enabling the characterization of magnetic arrangements beyond the reach of current molecular architectures. This surrogate modeling approach offers a pathway to explore and iteratively design tunable magnetic states in synthetic materials. The synthetic design, structural characterization, and quantum simulation framework established here defines a modular and scalable paradigm for probing the limits of engineered matter across chemistry, condensed matter, and quantum information science.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Scale-Up of World Record 16.5% CdTe Cell Design for a 50 MWp Production Facility: September 27, 2007 - March 26, 2009

This final report covers progress made on subcontract NAT-7-77015-07 by PrimeStar Solar Inc. for the 18 month period from September 27, 2007 through March 26, 2009. The project objectives were to accelerate the commercialization of the world record 16.5% efficiency cadmium telluride photovoltaic technology. This was done by developing high performance 6'x6' prototype mini-modules and by designingand commissioning a pilot line for manufacturing of commercial sized 60cmx120cm modules. This subcontract aligns with the SAI program by accelerating the development of high efficiency low cost CdTe solar PV module manufacturing. This will contribute to the goal of PV grid parity by 2015. Progress with the deliverables and milestones in this subcontract constitutes progress towards the KPP andmilestone objectives for the SAI program.

14 SOLAR ENERGY↗

Test Plan to Investigate the Optimal Cure Schedule of an Epoxy Resin for Its Application as an Adhesive in Optocouplers

Epoxy resins are polymeric materials that are known for their versatility, low cost, and strong thermal and mechanical properties. They can be used as coatings, adhesives, automotive primers, and have become staples in electronics, aerospace composites and semiconductor encapsulates. Recently, LANL has experienced a decline in the quality of a specialized electronic device, called an optocoupler, which is normally acquired from commercial suppliers. Because of this, a group at LANL is exploring the feasibility of in-house manufacturing of an optocoupler that is better suited for their application. The current prototype has resulted in adhesive failure after being exposed to several thermal cycles. There is a need to investigate the possible reasons for this failure, particularly how the cure schedule of the epoxy might affect its adhesive strength over time and in cycled temperatures. To assist in this investigation, a test plan has been developed involving multiple experiments using thermomechanical analysis (TMA), dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC).

36 MATERIALS SCIENCE↗

A Scalable Graph Analytics Framework for Programming with Big Data in R (pbdR)

Many disciplines such as biology, economics, engineering, physics, and the social sciences represent their data as graphs to capture patterns, trends, and associations. There are are many commercially available graph libraries in different programming languages to analyze these complex graphs. But there is no distributed graph library package in R - the popular statistical programming language to analyze graphs that bigger than a single machine's memory. Many domain experts prefer R over the numerous other alternatives. Towards this, we present a distributed graph analytics framework for R called programming with big graph using R (pBGR.) Our proposed framework leverages the Programming with Big Data in R (pbdR) ecosystem that provides scalable R packages for distributed computing in data science. We present an early prototype implementation of this framework using the distributed-memory parallel graph library CombBLAS and evaluate the framework's performance on leadership class computing platforms. Our experimental results demonstrate that the proposed framework is capable of performing large-scale parallel graph mining through the easyto-use R language. This enhanced graph processing capability coupled with other statistical tools already available in R, should be valuable to many domain experts.

Hasan, S M Shamimul↗

Design and Development of a Robotic Exoskeleton Device for use in Glove Boxes - 20374

Glovebox operators in nuclear facilities often operate under radioactive environment and typically perform monotonous, dull and repetitive work. This can result in muscle fatigue leading to increased levels of accidents. Current research work aims in assisting the glovebox operators by designing a novel upper limb exoskeleton device to reduce injuries and increase worker efficiency. Almost none of the commercially available hand and upper body exoskeletons are directly suitable for use in gloveboxes. This explains the novelty of the present work in developing a wearable powered robotic exoskeleton device. The device consists of electronics, motors and spring systems mounted on adjustable plates and is supported by a stationary frame behind the worker. The device is intended to be portable and adjustable according to the operator height. The elbow has a flexion movement assisted with motor control by way of a Bowden cable system. The system is floated on a spring and pulley combination that allows for extra safety and smoothness of operation. The end points are fixed near the pivot points to help minimize unwanted movement/torque. The extension movement of the upper and lower arm are assisted by gravity and a counter spring. The shoulder and upper arm movement are held in a neutral position with a spring system for counter balance allowing small movements within the glovebox. This initial concept considers only the vertical movement of the arm. The abduction and adduction movement will not be assisted or impeded by the over shoulder plate or at the forearm plate allowing for full range of motion. Several glovebox aspects such as the level of task assistance, ergonomic design, minimum hindrance in dexterity/operator movements and tear resistance for hazardous safety reasons will be considered in the design of the exoskeleton. Computer models will be simulated to test the load levels and stress conditions on the exoskeleton to enhance the designs. The exoskeleton focusses on major muscular involvement reduction through weight offset and active assistance with minimal parts and hence the device is derived with several joint links and contains both passive and active joints. The paper details the various stages in the design development and prototype testing of the exoskeleton device. Upon successful prototype device development, human testing will be conducted in a replica of the SRS-235F hot cell facility constructed at FIU-ARC. The final stage of the project will be potential testing/deployment of the exoskeleton device in one of the glovebox facilities in Savannah River Nuclear Waste site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DC-Link Current Minimization Control for Current Source Converter-Based Solid-State Transformer

This article proposes a fast predictive control method and a small DC-link inductor to minimize the DC-link current in current-source converter (CSC)-based solid-state transformer. The DC-link current minimization can significantly reduce power loss and improve efficiency. The challenge of this problem is on improving both steady-state and dynamic performance. PI control methods and large DC-link inductors are conventionally used in the CSC but have limited dynamic performance. A model predictive control (MPC) method is proposed to achieve switching-cycle-level settling time, and the DC-link inductor is sized for 40% ripple to enable fast current change. Importantly, this article also proposes to minimize the DC-link current by varying the current even within a line cycle under single-phase load to improve the steady-state performance, in contrast with the reduction to a constant value in the literature. The proposed MPC features a constant switching frequency without weighting factors. The MPC does not have a high computational burden and is implemented in a regular digital controller for a prototype of soft-switching solid-state transformer (S4T) with reduced conduction loss. The effectiveness of the proposed method has been experimentally verified on the SiC S4T prototype during steady-state and dynamics under different multiport power flow conditions up to 2 kV peak. Here, the DC-link current in the experiments is close to the minimum current with a short zero-vector duration, which further verifies the performance of the proposed method.

14 SOLAR ENERGY↗

SD-WAN Evaluation Criteria for a Defense Information Systems Network Expeditionary Customer Edge

The Defense Information Systems Agency (DISA) has identified a service provision gap midway between the capacity and capability of a Defense Information Systems Network (DISN) transport Edge Points of Presence (POP) and U.S. Department of Defense (DoD) Enterprise Classified Travel Kit (DECTK). Some deployed force 100-user Tactical Operations Centers are in field locations far removed from the DISN transport core, in challenging environmental conditions with limitations on space, weight, power, and cooling for network equipment. As part of a multi-phase project, Pacific Northwest National Laboratory (PNNL) will gather and analyze requirements, design, develop, prototype, and test a miniaturized and ruggedized DISN Customer Edge POP scaled to support approximately 100 users in a field Tactical Operations Center. An Expeditionary Customer Edge (ECE) will be more suitable for field deployment than a DISN transport Edge POP, using ruggedized hardware and network function virtualization (NFV) to operate in challenging field environmental conditions, plus reduce weight, power, and cooling requirements. A key enabling technology for ECE is Software Defined Wide Area Networking (SD-WAN). This document provides: • A brief overview of SD-WAN use cases and how they apply to ECE • How SD-WAN technology compares to existing networks like DISN that use Optical Transport Networking (OTN) and Multiprotocol Label Switching (MPLS) • SD-WAN functional requirements relevant to ECE • A description of an ECE Virtual Prototype, including simulated wide area network paths and a DISN-representative implementation of MPLS, in Cisco Modeling Labs • Detailed network flow walkthroughs • Evaluation criteria based on ECE-relevant SD-WAN functional requirements Finally, an appendix provides an informal evaluation of Speedify—a commercial retail Virtual Private Network service—against the ECE SD-WAN evaluation criteria.

42 ENGINEERING↗

The Dynamic Tunability of Memristor-Based Active Filters

When the memristor was fabricated for the first time, it launched an entirely new field of research. Many of the published papers regarding memristors are primarily theoretical and are based on computer simulations. Some recent papers analyze the memristor’s programming circuits, but to the best of the authors’ knowledge, no memristor has been embedded into a commercial analog circuit. This paper is practically oriented and it is based on the experimental results obtained by measurements on the circuit prototype. We present a solution for automated programming of a commercially available memristor and its implementation in tunable active bandpass filter design. The novelty of this paper is that the active bandpass filter’s central frequency could be programmed during the filter operation, so a pause for memristor state-switching is not required. The experimental results are promising, and open up possibilities for the memristor’s application in analog systems.

42 ENGINEERING↗

Advanced Reactors Thermal Energy Transport for Process Industries

The operation temperature of advanced nuclear reactors is generally higher than commercial light water reactors and thermal energy from advanced nuclear reactor can be used for various purposes such as liquid fuel production, district heating, desalination, hydrogen production, and other process heat applications, etc. Some of the major technology challenges that must be overcome before the advanced reactors could be licensed on the reactor side are qualification of next generation of nuclear fuel, materials that can withstand higher temperature, improvement in power cycle thermal efficiency by going to combined cycles, SCO2 cycles, successful demonstration of advanced compact heat exchangers in the prototypical conditions, and from the process side application the challenge is to transport the thermal energy from the reactor to the process plant with maximum efficiency (i.e., with minimum temperature drop). The main focus of this study is on doing a parametric study of efficient heat transport system, with different coolants (mainly, water, He, and molten salts) to determine maximum possible distance that can be achieved.

42 ENGINEERING↗

A Domestic Program for Liquid Metal PFC Research in Fusion

While high-Z solid plasma-facing components (PFCs) are the leading candidates for reactors, it is unclear that they can survive the intense plasma material interaction (PMI). Liquid metals (LM) PFCs offer potential solutions since they are not susceptible to the same type of damage, and can be “self-healing”. Following the Fusion Energy System Study on Liquid Metal Plasma Facing Components study that recently was completed by Kessel et al. (Fusion Sci Technnol 75:886, 2019) a domestic LM PFC design program has been initiated to develop reactor-relevant LM PFC concepts. This program seeks to evaluate LM PFC concepts for a Fusion Nuclear Science Facility (FNSF) or a Compact Pilot Plant via engineering design calculations, modeling of PMI and PFC components and laboratory experiments. The latter involves experiments in dedicated test stands and confinement devices and seeks to identify and answer open questions in LM PFC design. The new national LM PFC program is first investigating lithium as the plasma facing material for a flowing divertor PFC concept. Several flow speeds will be evaluated, ranging from ~ cm/s to m/s. The surface temperature will initially be held below the strongly evaporative limit in the first design; higher temperatures with strong evaporation will be considered in future concepts. Other topics of interest include: understanding of the hydrogen and helium interaction with the liquid lithium; single effect experiments on wetting, compatibility and embrittlement; and prototypical experiments for control and characterization of flowing LM. A path to plasma and future tokamak exposure of these concepts will be developed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

The New S-RAM Air Variable Compressor/Expander for Heat Pump and Waste Heat to Power Application

S-RAM Dynamics (S-RAM) has designed an innovative heat pump system targeted for commercial and industrial applications. This new heat pump system is more efficient than anything currently on the market and utilizes air as the refrigerant instead of hydrofluorocarbon (HFC) refrigerants, leading to lower operating costs, minimal environmental costs or concerns, and lower maintenance costs. The heat pumps will be manufactured in the United States. This project was aimed at determining the feasibility of utilizing additive manufacturing to make the heat exchanger device for the new heat pump system. ORNL and S-RAM Dynamics collaborated on determining the prototype performance and subsequently printing of the prototype using additive manufacturing. Complex heat exchanger designs were fabricated using the Arcam electron beam melting (EBM) powder bed technology using Ti-6Al-4V material. An ultrasonic welding system was utilized in order to remove the powder from the small openings of the heat exchanger. The majority of powder in the small chambers was removed, however, the amount of powder remaining in the heat exchanger was a function of geometry. Therefore, only certain geometries of heat exchangers could be fabricated. SRAM Dynamics evaluated a preliminary heat exchanger design. Although the results of the additive manufacturing of the heat exchanger were not optimum, a less complex geometry was demonstrated. A sleeve valve was used as a demonstration piece, as engine designs from S-RAM Dynamics require the engine to have a very high density. Preliminary designs of this geometry were successfully fabricated using the EBM technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Overview of NETL’s Low Temperature CO2 Electrolysis Research

This keynote lecture will briefly overview diverse research areas of National Energy Technology Laboratory (NETL) to advance energy and environmental sustainability along with carbon management. Our electrochemistry efforts on carbon conversion directly support the US goal of achieving carbon-free power sector by 2035 and net zero emissions by 2050. Since CO2 electroreduction is highly structure-sensitive, NETL ongoing research has been focused on the rational design and engineering of electrocatalysts to facilitate the CO2 conversion to desirable products with good selectivity, activity, and durability. Different classes and types of electrocatalytic materials will be covered in this talk, from well-defined atomic-scale model catalysts to heterogenous, scalable powder systems at nano- and micro-scale for “real world” performance evaluation. Several spectroscopic, microscopic, and electrochemical characterization techniques along with computational findings will be additionally discussed to gain more insights into the structure-activity relation. The last part of this seminar will provide more detail on how NETL has transitioned from the most common aqueous H-type reactor for lab-scale validation to more realistic full electrolyzer cell in bench-scale prototype. The knowledge, electrocatalytic materials, and device validation achieved from NETL in-house research will be translated to industrial sector for large scale deployment and the anticipated outcome will help advance the development of low temperature CO2 electrolysis technologies.

Nguyen Phan, Thuy Duong↗

Mu2e Tracker's Gas Connection

This report is a resume of the activities in which I was involved during my internship at Fermilab Particle Physics and Accelerator Laboratory in Batavia. The experiment at whom my work is connected is the Mu2e experiment, in particular I worked in the Tracker’s group. The main task of my training program was to design a gas service connection that take place in a small volume located between the Tracker and the Calorimeter (two main elements that constitute the detector). During the initial phase I was lightly trained about the experiment and its general design, then I was supervised on my specific task. All the work aimed to reach a design solution that could meet all the BCs, in this view, a reasonable solution was prototyped and tested. The tests performed at Lab 3 were another fundamental aspect of my experience at Fermilab closing the circle of studying, modelling, machining and testing. I want to thank primarily Aseet Mukherjee and Mete Yucel that were my supervisors, they constantly spent their time attempting to create a favourable workplace, suggesting, listening and meeting all the requests in short time, working for them was absolutely like "working with them", without their help achieve the result would been greatly harder. Giuseppe Gallo deserve a special thanks too for revising mostly of my work and being always available for support. I had also the chance to share my work during the "Weekly Tracker’s Meetings" dealing with other bright engineers and physicists, between them I really appreciate George Ginter, Russel Rucinski, Yujing Sun and Waqar Ahmed. I want also to express my gratitude to Simone Donati, Giorgio Bellettini and Emanuela Barzi that make this unique experience possible organizing this program for decades. Thanks to my Mother, my Father, my Brother, my Nephew, my uncle Damiano and my friend Simona always near, never stopping to dream with me.

43 PARTICLE ACCELERATORS↗