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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Direct Discontinuous Galerkin methods for the reacting multi-component flow equations

The Direct Discontinuous Galerkin (DDG (Liu and Yan, 2008)) method and a counterpart with Interface Correction (DDGIC (Danis and Yan, 2022)) are extended to compute diffusion terms that arise when solving the compressible multi-component flow equations in thermochemical nonequilibrium. Thermodynamic properties, transport properties, chemical reaction rates, and energy exchange terms are computed using Mutation++ (Scoggins et al., 2020). The DG method is applied on unstructured grids, where the accuracy and convergence rates can be sensitive to the numerical method chosen for parabolic terms. A method for determining the homogeneity tensor of the flow equations required for DDGIC is shown. The convergence properties of the DDG methods are studied and compared to the Interior Penalty (IP) method. A number of numerical experiments are conducted to assess the accuracy and performance of the method. The numerical results and convergence studies indicate that DDG and DDGIC provide accurate solutions and perform well for general flows in thermochemical nonequilibrium.

Diffusion↗
NASA NTRS2004

Ionic Liquids and New Proton Exchange Membranes for Fuel Cells

There is currently a great surge of activity in fuel cell research as laboratories across the world seek to take advantage of the high energy capacity provided by &el cells relative to those of other portable electrochemical power systems. Much of this activity is aimed at high temperature fie1 cells, and a vital component of such &el cells must be the availability of a high temperature stable proton-permeable membrane. NASA Glenn Research Center is greatly involved in developing this technology. Other approaches to the high temperature fuel cell involve the use of single- component or almost-single-component electrolytes that provide a path for protons through the cell. A heavily researched case is the phosphoric acid fuel cell, in which the electrolyte is almost pure phosphoric acid and the cathode reaction produces water directly. The phosphoric acid fie1 cell delivers an open circuit voltage of 0.9 V falling to about 0.7 V under operating conditions at 170 C. The proton transport mechanism is mainly vehicular in character according to the viscosity/conductance relation. Here we describe some Proton Transfer Ionic Liquids (PTILs) with low vapor pressure and high temperature stability that have conductivities of unprecedented magnitude for non-aqueous systems. The first requirement of an ionic liquid is that, contrary to experience with most liquids consisting of ions, it must have a melting point that is not much above room temperature. The limit commonly suggested is 100 C. PTILs constitute an interesting class of non-corrosive proton-exchange electrolyte, which can serve well in high temperature (T = 100 - 250 C) fuel cell applications. We will present cell performance data showing that the open circuit voltage output, and the performance of a simple H2(g)Pt/PTIL/Pt/O2(g) fuel cell may be superior to those of the equivalent phosphoric acid electrolyte fuel cell both at ambient temperature and temperatures up to and above 200 C. My work at NASA Glenn Research Center during this summer is to develop and characterize proton exchange membranes doped with ionic liquids. The main techniques used to characterize these materials are: Impedance Spectroscopy, NMR, DSC, TGA, DMA, IR, and SEM ...

Belieres, Jean-Philippe↗
DOE OSTI2026

Bipolar Membranes Electrodialysis for Water Purification and Resource Recovery

Reverse osmosis concentrate (ROC) from inland brackish water desalination and wastewater recycling presents moderate salinity, posing significant challenges for treatment and disposal. Existing treatment technologies predominantly rely on energy-intensive thermal methods, large-area evaporation strategies, or deep-well disposal, which often result in the loss of water value. Electrified membrane brine treatment offers a promising alternative by utilizing renewable energy sources, enabling complete water recycling. This work proposes the development of next-generation bipolar membrane electrodialysis (BMED) systems capable of desalinating brine while simultaneously recovering valuable resources. However, several critical challenges remain in the areas of membrane engineering for BMED. These include: 1) decreased current efficiency during desalination due to the low conductivity of feed chambers, 2) fouling and scaling from multivalent ions and contaminants in the feed, and 3) the retention and carryover of ROC contaminants, including PFAS compounds. Our research focuses on the development of novel anion exchange membranes (AEMs) and cation exchange membranes (CEMs) based on synthesized multiblock copolymers. We investigate the effects of block length, ion exchange capacity (IEC), and polymer backbone structure on cation and anion transport (e.g., Na+, Cl-, OH-, H+) for both our synthesized membranes and commercial membranes. Fundamental properties of these membranes, such as water uptake, IEC, and ionic conductivity, are also evaluated to optimize performance for BMED applications.

08 HYDROGEN↗
NASA NTRS2021

PEM Fuel Cell MODEL for Conceptual Design of Hydrogen eVTOL Aircraft

A model and software for design and analysis of a Proton Exchange Membrane fuel cell (PEMFC) system are developed for hydrogen eVTOL aircraft. Examples are provided of stacks designed for 80 kWe and 500 kWe net electrical power. Examples are provided of eVTOL designed for 250 and 400 lb payload. The trade-offs included stack characteristics, hydrogen storage characteristics, and aircraft payload and range. The objectives were to identify the key technology drivers of a hydrogen rotorcraft, establish technology targets for a viable aircraft, and recommend research to address the fundamental pre-competitive barriers. The current U.S. infrastructure on hydrogen informed the targets and recommendations. The key conclusion is that the advances made in cell electrochemical power density over the last decade might allow a PEMFC system to meet, or even beat, piston engine powered light-utility rotorcraft. The development must focus on the key drivers of a hydrogen eVTOL. The drivers are ultra-light stack cooling and short-term hydrogen storage. A stack system of net electrical power 100−150 kWe with specific power 1.1 kWe/kg including air, cooling, and electrical subsystems, and a tank storage of 15% weight fraction hydrogen are the minimum targets to meet the performance of a modern piston-engine rotorcraft, with a range of 180 nautical miles, payload of 400 lb, and gross weight of about 1400 lb. This is defined as the objective aircraft. If only one target is met, an aircraft of half the range could be produced, with a 30% greater gross take-off weight. This is defined as an intermediate aircraft. Because definitive conclusions are premature without weights and loads data on a flight-worthy stack system, it is recommended that a fuel cell powered hydrogen eVTOL demonstrator be built and flown. The existing hydrogen infrastructure for cars provide ample opportunity to create a pilot program. About 12 metric tons of retail hydrogen are available for cars every day in California, which is less than 0.05% of the yearly hydrogen production in the U.S.. A hypothetical fleet of 100 aircraft, operating 3 flights a day, would increase the demand by 2.25 tons per day and require 140 MWh of renewable electricity for green hydrogen.

PEM↗
DOE OSTI2012

Energy Efficient Microwave Hybrid Processing of Lime for Cement, Steel, and Glass Industries

In this study, the microwave materials interactions were studied through dielectric property measurements, process modeling, and lab scale microwave hybrid calcination tests. Characterization and analysis were performed to evaluate material reactions and energy usage. Processing parameters for laboratory scale and larger scale calcining experiments were developed for MAT limestone calcination. Early stage equipment design concepts were developed, with a focus on microwave post heating treatment. The retrofitting of existing rotary calcine equipment in the lime industry was assessed and found to be feasible. Ceralink sought to address some of the major barriers to the uptake of MAT identified as the need for (1) team approach with end users, technology partners, and equipment manufacturers, (2) modeling that incorporates kiln materials and variations to the design of industrial microwave equipment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗
DOE OSTI2014

Superficial Carbon Dioxide Brayton Cycle Energy Conversion Research and Development Program

A closed Brayton cycle recirculates the working fluid, and the turbine exhaust is used in a recuperating heat exchanger to heat the turbine feed. A "supercritical cycle' is a closed Brayton cycle in which the working fluid, such as supercritical carbon dioxide (s-0O2), is maintained near the critical point during the compression phase of the cycle. The key property of the fluid near its critical point is its higher gas density, closer to that of a liquid than of a gas, allowing for the pumping power in the compressor to be significantly reduced, which results in thermal efficiency that is significantly improved over the efficiency attainable in an ideal-gas Brayton cycle. Another advantage of using a supercritical cycle is that the overall footprint of the power-conversion system can be significantly reduced, as compared to the same power output of a steam-Rankine cycle, due to the high pressure in the system and resulting low volumetric flow rate. This allows for the heat-rejection heat exchanger and turbine to be orders of magnitude smaller than for similar power output steam-Rankine systems. Other potential advantages are the reduced use of water, not only due to the increased efficiency, but due also to the fact that the heat rejection temperature is significantly higher than for steam-Rankine systems, allowing for significant heat rejection directly to air. In 2006, Sandia National Laboratories (SNL), recognizing these potentially significant advantages of a higher efficiency power cycle, used internal funds to establish a testing capability and began partnering with the U.S. Department of Energy Office of Nuclear Energy to develop a laboratory-scale test assembly to show the viability of the underlying science and demonstrate system performance. Since that time, SNL has generated over 100 kW-hours of energy, verified cycle performance, and developed cycle controls and maintenance procedures. The test assembly has successfully operated in different configurations (simple Brayton, waste heat cycle, and recompression) and tested additives to the s-CO 2 working fluid. However, challenges remain to confirm viability of existing components and suitability of materials, demonstrate that theoretical efficiencies are achievable, and integrate and scale up existing technologies to be suitable for a range of applications.

42 ENGINEERING↗
DOE OSTI2014

High speed measurements of neutral beam turn-on and impact of beam modulation on measurements of ion density

Modulation of neutral beams on tokamaks is performed routinely, enabling background rejection for active spectroscopic diagnostics, and control of injected power and torque. We find that there exists an anomalous initial transient in the beam neutrals delivered to the tokamak that is not accounted for by the accelerator voltage and power supply current. Measurements of the charge-exchange and beam photoemission on the DIII-D tokamak [J. L. Luxon, Nucl. Fusion 42, 614 (2002)] at high speed (200 μs) reveal that the energy of the beam neutrals is constant, but the density of beam neutrals displays dramatic variation in the first 2–3 ms following beam turn-on. The impact of this beam density variation on inferred ion densities and impurity transport is presented, with suggested means to correct for the anomalous transient.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Numerical Modeling & Size Optimization of Thermal Energy Storage for Iron & Steel Production

Iron and steel production are responsible for 90 million MtCO2 per year in the United States. Hydrogen direct reduction of iron (H2DRI) is a promising pathway for a more sustainable iron production than commercially deployed technologies which rely on natural gas. The H2DRI process requires hydrogen at a temperature of up to 950 degrees C fed into a reduction furnace to produce pellets or briquettes that are used in the downstream iron and steelmaking process. In this work, we propose to use an electrical thermal energy storage (ETES) system, that can use renewable electricity to store high-temperature heat and dispatch it upon demand. Such a system can buffer the H2DRI plant from the variability of electricity prices by charging during curtailment and running the plant from storage during times of peak electricity price. We have developed heat transfer models for two different ETES systems that can be used to heat up hydrogen to the required temperatures: a particle-based ETES and a firebrick ETES. These models are used to evaluate the performance of such a system and support the sizing and preliminary cost estimation. The preliminary results using both models show that designing ETES systems for an industrial-scale H2DRI furnace is feasible. The firebrick ETES system has limited operational duration, which might limit the price buffering effect unless significantly oversized. The particle ETES system heat exchanger has industry-feasible dimensions, but its storage capacity would be decided upon the number of particle storage silos.

25 ENERGY STORAGE↗
DOE OSTI2025

Optimizing Hybrid-Phase IrO2 Catalysts with Ti for Enhanced Oxygen Evolution Reaction for Proton Exchange Membrane Water Electrolysis

To realize a sustainable energy transition, water electrolysis-particularly proton exchange membrane water electrolysis (PEMWE)-holds significant promise. However, practical deployment is hindered by the cost and instability of the anode catalyst, IrO2. Recent studies indicate that tuning the Ir-O bond distance, via doping or composite formation, is key to enhancing the oxygen evolution reaction (OER) performance of IrO2-based electrocatalysts. Herein, a hybrid-phase Ti-incorporated IrO2 electrocatalyst is developed, exhibiting outstanding OER activity (298.8 mV at 100 mA cm-2) and stability over 25 h. This improvement originates from asymmetric interatomic interactions introduced by Ti, as revealed by combined experimental X-ray analyses and theoretical modeling. Ti incorporation induces tensile strain along the z-axis in IrO2 motifs, effectively reducing the average Ir-O bond distance and thereby enhancing OER activity. In situ X-ray absorption spectroscopy further confirms that at 1.5 V (vs. RHE), the elongated Ir-O bond facilitates -OOH* intermediate formation while suppressing Ir dissolution, contributing to superior stability. These findings underscore the critical role of Ir-O bond engineering in balancing activity and durability, offering strategic insights for the rational design of high-performance OER catalysts for renewable energy technologies.

08 HYDROGEN↗
DOE OSTI2022

Automation of FARM from Alpha Phase to Beta Phase

Integrated energy systems (IES) combine different energy technologies in synergistic ways to achieve a more secure and economical energy supply. The RAVEN-based HYBRID framework and the RAVEN plugin for grid and capacity optimization (HERON) are used to find the optimal installed capacity and the optimal economical dispatch of each component of the IES, by respecting the limits on the production variables and the corresponding rates of variation (explicit constraints). Besides, there are other process variables whose evolution needs to be bounded to avoid damaging the components (e.g., condensers, heat exchangers, steam generators, etc.) or degrading the process efficiency (e.g., electrolysis in the hydrogen production process). To avoid violating these latter limits (implicit constraints), a proof-of-concept HERON validator based on Feasible Actuator Range Modifier (FARM-Alpha) was developed by Argonne National Laboratory in January 2021. This FARM-Alpha validator calculates the evolution of process variables on whom the implicit constraints are placed, and then provides feedback to HERON dispatcher to adjust the power setpoints of three IES components, i.e., Balance of Plant, Secondary Energy Source, and Thermal Energy Storage, so as to meet both the explicit and implicit constraints. FARM-Alpha was designed to assess the performance of FARM as a HERON validator only, i.e., the list of components and implicit operational constraints were hard-coded within the source code. The lack of flexibility of the corresponding software structure does not allow the deployment in production environment. This report describes the development and the implementation of an enhanced version of the FARM-based validator (FARM-Beta), which ensures more flexibility for the end user in modeling multiple IES configurations and scenarios. Several test cases of the power dispatch problem were then selected to demonstrate the capabilities offered by FARM-beta. The test cases illustrate the efficiency of the closed-loop optimization scheme and the capability to calculate set-point trajectories satisfying both explicit and implicit constraints.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Influence of design and operating parameters for additively manufactured intensified packing devices on CO 2 -Absorption column cooling and capture efficiency

Solvent-based CO 2 absorption is technologically a matured CO 2 capture pathway but suffers from: high regeneration energy demand, and solvent temperature rise and decreased capture efficiency caused by the heat of reaction. While research has focused on developing non-aqueous and low-aqueous solvents for decreasing the regeneration energy, the temperature bulge due to exothermic absorption is typically dealt with by cooling the solvent with an external inter-stage heat-exchanger. This approach may increase the overall process footprint, as well as capital and operating costs. Here, the current study explores a process intensification approach by incorporating inside the column an additively manufactured intensified packing device that consists of corrugated plates and internal coolant channels. The corrugated plates provide surface area for mass transfer between gas and liquid, while cooling fluid inside the internal channels removes heat from the exothermic reactive system. Two different intensified devices with specific surface areas of 266 m 2 /m 3 and 359 m 2 /m 3 were designed, manufactured, and tested inside a 2.06-m long and 0.203-m diameter column packed with commercial Mellapak 250Y packing. The device with a lower surface area showed up to 27 % reduction in cooling performance. A steady-state heat transfer model provides good agreement with the experimental column temperature and intra-stage heat removal data. Although a decrease in heat transfer performance was observed for the device with lower surface area, CO 2 capture experiments performed with simulated flue gas and low-aqueous solvent demonstrated that both intensified devices lead to a similar improvement of 12 % in capture efficiency. This study provides an understanding on simplifying the intensified packing device geometry and decreasing the device fabrication cost by 25 % without compromising with the CO 2 absorption performance of the packed column.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Comparative experimental study of heat transfer processes in accumulation energy recovery exchangers

In this study, an experimental comparison between three different energy accumulating ceramic heat exchangers for energy recovery in ventilation systems was presented. The units were selected to represent three different approaches on the energy recovery process: honeycomb structure with more accumulation mass (more energy can be stored in one unit)- Unit 1.1, honeycomb structure with lower accumulation mass- Unit 1.2, and a rectangular structure with expanded heat transfer surface- Unit 1.3. The achieved results are useful for the future application of such units in ventilation systems. It was established that all evaluated units demonstrated an acceptable effectiveness of thermal energy recovery from the exhaust air. Their average energy recovery efficiency ranged between 70 % and 80 %, aligning with expected performance benchmarks for regenerative heat exchangers employed in contemporary mechanical ventilation systems. It was also established that the factor which has the highest impact on thermal effectiveness is the heat transfer surface available in the tested heat exchangers. Units with the highest number of channels (i.e., with the highest amount of single channel walls, which can be used for heat transfer) achieve the highest thermal effectiveness. However, higher thermal effectiveness can negatively affect the ventilation potential of the units. Unit 1.3, which was characterized by the highest thermal efficiency, was also characterized by the lowest achievable flow rate. It was also found that the important technical aspect that should be taken into account when analyzing accumulation energy recovery units is also the fluctuation of the supply air temperature. The ability to ensure minimal temperature fluctuations is a significant operational advantage, as it ensures a higher level of safety at lower outside temperatures.

Energy recovery↗
DOE OSTI2021

Kinetic equilibrium reconstructions of plasmas in the MAST database and preparation for reconstruction of the first plasmas in MAST upgrade

Reconstructions of plasma equilibria using magnetic sensors were routine during operation of the Mega Ampere Spherical Tokamak (MAST) device, but reconstructions using kinetic profiles were not. These are necessary for stability and disruption analysis of the MAST database, as well as for operation in the upgrade to the device, MAST-U. The three-dimensional (3D) code VALEN is used to determine eddy currents in the 3D vessel structures for vacuum coil test shots, which are then mapped to effective resistances in the two-dimensional vessel groupings in the EFIT equilibrium reconstruction code to be used in conjunction with nearby loop voltage measurements for estimated currents in the structures during reconstruction. Kinetic equilibrium reconstructions with EFIT, using all available magnetic sensors as well as Thomson scattering measurements of electron temperature and density, charge exchange recombination spectroscopy measurements of ion temperature, and internal magnetic field pitch angle measurements from a motional Stark effect (MSE) diagnostic are performed for a large database of MAST discharges. Excellent convergence errors are obtained for the portions of the discharges where the stored energy was not too low, and it is found that reconstructions performed with temperature and density measurements but without MSE data usually already match the pitch angle measurements well. A database of 275 kinetic equilibria is used to test the ideal MHD stability calculation capability for MAST. In conclusion, the necessary changes to conducting structure in VALEN, and diagnostic setup in EFIT have been completed for the upgrade from MAST to MAST-U, enabling kinetic reconstructions to commence from the first plasma discharges of the upgraded device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Integrated Cyber/Physical Impact Analysis to secure US Critical Infrastructure

In a common electric power plant, heat is used to boil water into steam which drives a turbine. The steam from the turbine outlet is condensed with cooling water. This is the common Rankine cycle and, even after decades of development is relatively inefficient and water intensive. Alternatively, a closed Brayton cycle recirculates the working fluid, and the turbine exhaust is used in a recuperating heat exchanger to heat the turbine feed. A "supercritical cycle' is a closed Brayton cycle in which the working fluid, such as supercritical carbon dioxide (sCO2), is maintained above the critical point during the compression phase of the cycle. The key property of the fluid near its critical point is its higher gas density, closer to that of a liquid than of a gas, allowing for the pumping power in the compressor to be significantly reduced resulting in improved efficiency. Other advantages include smaller component size and the reduced use of water, not only due to the increased efficiency, but also due sensible heat rejection which facilitates dry air cooling compared to air-cooled steam condensers. A Sandia National Laboratories commercialization review concluded that the technology has applicability across various power generation applications including fossil fuels, concentrated solar power and nuclear power. In 2006, Sandia National Laboratories (SNL), recognizing the potential advantages of a higher efficiency power cycle, used internal funds to establish a testing capability and began partnering with the U.S. Department of Energy Office of Nuclear Energy to develop a laboratory-scale test assembly to show the viability of the underlying science and demonstrate system performance. Since that time, SNL has generated power, verified cycle performance, and developed cycle controls and maintenance procedures. The test assembly has successfully operated in different configurations (simple Brayton, waste heat cycle, and recompression) and tested additives to the s-CO2 working fluid. Our current focus is to partner with industry and develop cycle components and control strategies sufficient to support a successful commercial offering. This paper has been developed for the Energy Policy Institute's (EPI's) 6th Annual Energy Policy Research Conference scheduled for 8 & 9 September 2016 in Santa Fe, NM. We describe the cycle in more detail and describe specific benefits and applications. The paper will also include current technology development activities and future plans.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1991

Design considerations for space radiators based on the liquid sheet (LSR) concept

Concept development work on space heat rejection subsystems tailored to the requirements of various space power conversion systems is proceeding over a broad front of technologies at NASA LeRC. Included are orbital and planetary surface based radiator concepts utilizing pumped loops, a variety of heat pipe radiator concepts, and the innovative liquid sheet radiator (LSR). The basic feasibility of the LSR concept was investigated in prior work which generated preliminary information indicating the suitability of the LSR concept for space power systems requiring cycle reject heat to be radiated to the space sink at low-to-mid temperatures (300 to 400 K), with silicon oils used for the radiator working fluid. This study is directed at performing a comparative examination of LSR characteristics as they affect the basic design of low earth orbit solar dynamic power conversion systems. The power systems considered were based on the closed Brayton (CBC) and the Free Piston Stirling (FPS) cycles, each with a power output of 2 kWe and using previously tested silicone oil (Dow-Corning Me2) as the radiator working fluid. Conclusions indicate that, due to its ability for direct cold end cooling, an LSR based heat rejection subsystem is far more compatible with a Stirling space power system than with a CBC, which requires LSR coupling by means of an intermediate gas/liquid heat exchanger and adjustment of cycle operating conditions.

Juhasz, Albert J.↗
DOE OSTI2015

A lab-based ambient pressure x-ray photoelectron spectrometer with exchangeable analysis chambers

Ambient pressure X-ray photoelectron spectroscopy (APXPS) is a powerful spectroscopy tool that is inherently surface sensitive, elemental, and chemical specific, with the ability to probe sample surfaces under Torr level pressures. Herein, we describe the design of a new lab-based APXPS system with the ability to swap small volume analysis chambers. Ag 3d(5/2) analyses of a silver foil were carried out at room temperature to determine the optimal sample-to-aperture distance, x-ray photoelectron spectroscopy analysis spot size, relative peak intensities, and peak full width at half maximum of three different electrostatic lens modes: acceleration, transmission, and angular. Ag 3d(5/2) peak areas, differential pumping pressures, and pump performance were assessed under varying N{sub 2}(g) analysis chamber pressures up to 20 Torr. The commissioning of this instrument allows for the investigation of molecular level interfacial processes under ambient vapor conditions in energy and environmental research.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗