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At least 109 records · Page 6

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DOE OSTI2022

Standard operating procedure for post-operation component disassembly and observation of benchtop water electrolyzer testing

Post-operation component disassembly and observation of electrolyzer parts is useful in understanding the interactions of the components and the electrochemical environment beyond the systems electrochemical output. We report a standard protocol for post-operation component disassembly and observation, including directions for cell-component preservation, preliminary visual inspection of cell components, and a guide for the advanced inspection of specific components with suggestions for further analysis if necessary. The procedures outlined here allow for a standardized method that can be used and compared between different laboratories and for literature comparison to experimental results.

03 NATURAL GAS↗

DOE OSTI2023

Quantitation of olefins in sustainable aviation fuel intermediates using principal component analysis coupled with vacuum ultraviolet spectroscopy

Olefins, a common intermediate from biomass conversion processes, are undesirable in jet fuel because of their poor thermal stability. This paper presents an approach for olefin quantitation using 2D gas chromatography coupled with vacuum ultraviolet spectroscopy. Principal component analysis was used to reduce the dimensionality of the spectroscopic data from a highly olefinic fuel intermediate. A principal component template was created that enabled olefin quantitation, which was compared to the existing GCxGC-VUV approach from the literature. The principal component method was able to identify and quantify trace amounts of cyclodienes, which were present at only 0.01 wt% in the fuel sample. The principal component approach also identifies species that fall outside of the GCxGC template. For instance, quantitation with the literature method resulted in an olefin concentration of 0.95 times that of the principal component method due to olefins falling outside of the expected GCxGC regions. The principal component results were compared with 13 C and 1 H NMR data, which confirmed that the fuel had a high concentration of olefins and alkanes with little aromatic content.

Kosir, Shane↗

DOE OSTI2022

Influence of Cryomilling on Crystallite Size of Aluminum Powder and Spark Plasma Sintered Component

The present investigation aims to develop nanocrystalline (NC) pure aluminum powders using cryomilling technique and manufacture bulk components using spark plasma sintering (SPS). The cryomilling was performed on pure Al powders for 2, 6, and 8 h. The cryomilled powders were then consolidated using SPS to produce bulk components. The particle morphology and crystallite size of the powders and the bulk SPS components were analyzed using scanning electron microscopy (SEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results showed that the crystallite size of pure Al powders decreases with increased cryomilling time. The results also showed that the SPS at elevated temperatures resulted in a slight increase in crystallite size, however, the changes were insignificant. The mechanical properties of the bulk components were determined using a Vickers microhardness tester. The hardness of the cryomilled SPS component was determined to be three times higher than that of the unmilled SPS component. The mechanism for the reduction in crystallite size with increasing cryomilling time is discussed. This fundamental study provides an insight into the development of bulk nanomaterials with superior mechanical properties for automotive, aerospace, marine, and nuclear applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Force-triggered, Bio-based, Sealants for Prefabricated Building Components: Towards Improved Efficiency, Performance and Sustainability

The prefabricated building construction industry has made extensive progress in expediting the manufacture of prefabricated components at offsite plants. However, this progress has not translated to the assembly of the prefabricated components at the construction site. Case in point, sealing the joints between components to prevent air leaks requires the manual application of tape, caulk, or spray foam at the jobsite, and performance is highly dependent on the skills of the installer. To reduce assembly time and improve the airtightness and waterproofness of prefabricated components, we developed a sealant that can be installed at the plant and have its curing reaction triggered at the jobsite. Additionally, we used this opportunity to explore the use of bio-based feedstocks that are abundant and not used for food. We evaluated a series of force-triggered, bio-based, high strength, and fast curing sealants, consisting of a one-part heterogeneous system. These sealants are derived from formulations with ≥80% of bio-based components, consisting of a cardanol derived diepoxy that is microencapsulated in a polymer shell and embedded in a cardanol derived amine curing agent. The microcapsule shell allows separation of the reactive species in the one-part sealant allowing a fast-curing system to remain unreacted until the right trigger is applied. When the microcapsules are activated and broken by force, the highly reactive species mix and cure, exhibiting peel strengths up to 143 ppi. The open-air shelf stability of the sealant complexes was demonstrated by peel strength values of ~16 ppi when triggering the curing reaction even after being exposed for 8 months to open air and humidity. The successful on-demand triggering of curing reactions and the shelf stability provide efficacy of these force-triggered sealants for installation on prefabricated components, storage for months prior to delivery, and assembly at the jobsite. These force-triggered bio-based sealants for prefabricated buildings could result in lower installation time and cost as well as better performance than tapes and caulks at the jobsite.

Cortes Guzman, Karen [ORNL] (ORCID:000000028793468↗

DOE OSTI2020

How Wrong Can the Operational AEP Uncertainty Estimate Be When We Ignore the Correlations Between the Uncertainty Components?

Calculations of wind farm annual energy production (AEP) on operational data are essential for a variety of financial transactions during the life of wind plants. The AEP estimate is associated with an uncertainty value, which is calculated by combining contributions connected to on-site measurements, long-term reference measurements, losses, regression, windiness adjustment, and wind resource interannual variability. Although very limited documentation on the topic exists, the conventional approach currently used by the wind energy community to assess the uncertainty connected to the operational AEP estimate assume that the different uncertainty components are uncorrelated and therefore calculates the overall uncertainty with a sum of squares approach. In this analysis, we contrast the traditional technique to estimate the overall AEP uncertainty by ignoring the correlation between its different components with a novel Monte Carlo based approach, which can instead take into account the correlation between different uncertainty categories. We consider monthly operational data from 472 wind farms from the Energy Information Administration (EIA) 923 database to assess the difference between the two approaches. Long-term wind speed data needed for the AEP assessment are taken from three reanalysis products: the Modern-Era Retrospective analysis for Research and Applications v2 (MERRA-2), the European Reanalysis Interim (ERA-interim), and the National Centers for Environmental Prediction v2 (NCEP-2). The results of the Monte Carlo approach show that three pairs of AEP uncertainty components do show a statistically significant correlation: the uncertainty connected with wind resource inter-annual variability is positively correlated with the one related to the windiness correction and negatively correlated with the one due to the regression, and the wind measurement uncertainty is positively correlated with the regression uncertainty. All these correlations, which are found between uncertainty components which are not only part of an operational analysis, but also of a wind resource assessment, are currently ignored in the conventional techniques used as industry standard. We further investigate the causes of these correlations, in terms of common dependencies of different uncertainty components on wind resource variability, number of data points, and quality of the regression between wind speed and energy production data. Next, we quantify the error in the current industry standard technique, in terms of the percentage difference in total uncertainty calculated with the two considered approaches, for all the analyzed wind farms. We find a mean absolute percentage difference of about 6%, with the largest differences being greater than 20%. The data clearly confirm that ignoring the actual correlation between the uncertainty components can lead to large errors in the assessment of the operational AEP uncertainty, and the proposed Monte Carlo approach should be preferred.

Monte Carlo↗

DOE OSTI2022

Devices and methods for separating components

A method, system, and device for separating components is described. A vessel is provided. A first volume of a process liquid, containing a first component and a second component, is passed into an inner chamber. The piston retracts to a first position. The fluid inlet is closed. The piston is retracted to a second position, causing the first component and a first portion of the second component to flash to form a vapor stream while a second portion of the second component freezes to form a solid product stream. The fluid outlet is then opened. The piston is advanced to a third position that results in a third volume, smaller than the first volume, such that the vapor stream is expelled. The fluid outlet is closed. The piston is fully closed such that the solid product stream is pressed into and extruded through the solids outlet.

Baxter, Larry↗

DOE OSTI2023

FINITE ELEMENT MODEL MESH REFINEMENT EFFECTS ON QUALIFICATION OF NUCLEAR GRADE GRAPHITE COMPONENTS

The American Society of Mechanical Engineers (ASME) provides the full and simplified design-by-analysis probabilistic assessments for determining acceptance of nuclear grade graphite core components. The assessments can be characterized by three parts: (1) a component stress distribution, often determined by a finite element (FE) model; (2) a Weibull probability density function (pdf) that characterizes the experimental tensile strength distribution; and (3) the post-processor, which combines the FE model and the Weibull strength distribution in accordance with the full and simplified assessments to determine component acceptance. It is known that the level of mesh refinement in FE models can affect the modeled component’s calculated stress distribution. Depending on the component geometry, the stress distribution may converge with sufficient refinement. It was previously unknown whether the acceptance decision resulting from the full and simplified assessments might change even with sufficient mesh refinement. This study explores that question using experimental strength results for a dog-bone geometry for two graphite grades, IG-110 and PCEA. The simplified assessment has two criteria that must be met, the first limits the combined membrane stress by the allowable stress and the second limits the peak equivalent stress by the allowable stress scaled by the ratio of flexural to tensile strength. In the application of the simplified assessment, convergence of the peak equivalent stress required extreme mesh refinement, however, the acceptance decision was not affected. It is hypothesized that more complex geometries with stress concentrations may present mesh refinement effects on the simplified assessment acceptance decision. Mesh refinement did affect the acceptance decision in the full assessment for the applied pressure loadings in this study. This work suggests component stress distribution convergence is not a sufficient criteria for POF convergence in the full assessment and that mesh refinement should continue until the POF has converged, especially where the resulting POF is bordering the SRC acceptable POF limit.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Identification and Evaluation of Thermal Transport Components for Integrated Energy Systems

A proper evaluation and selection of component technologies is a critical aspect in the development of Integrated Energy System (IES). This study aims to investigate the key components and associated technologies required to build high-temperature heat transport systems for IES. Of particular interest is the component technologies needed to design and construct IES that combines advanced nuclear reactors with high-temperature industrial processes. This study particularly delved into knowledge base, evaluation metrics, and state-of-the-art commercial technologies, aiming to facilitate the evaluation and selection process of various thermal transport components. In addition, an evaluation process was proposed in order to assist in the optimal selection of the thermal transport components based on the knowledge base and evaluation metrics investigated through this study.

42 ENGINEERING↗

DOE OSTI2021

Coupling Mesoscale Budget Components to Large-Eddy Simulations for Wind-Energy Applications

To simulate the airflow through a wind farm across a wide range of atmospheric conditions, microscale models (e.g., large-eddy simulation, LES, models) have to be coupled with mesoscale models, because microscale models lack the atmospheric physical processes to represent time-varying local forcing. Here we couple mesoscale model outputs to a LES solver by applying mesoscale momentum- and temperature-budget components from the Weather Research and Forecasting model to the governing equations of the Simulator fOr Wind Farm Applications model. We test whether averaging the budget components affects the LES results with regard to quantities of interest to wind energy. Our study focuses on flat terrain during a quiescent diurnal cycle. The simulation results are compared with observations from a 200-m tall meteorological tower and a wind-profiling radar, by analyzing time series, profiles, rotor-averaged quantities, and spectra. However, while results show that averaging reduces the spatio-temporal variability of the mesoscale momentum-budget components, when coupled with the LES model, the mesoscale bias (in comparison with observations of wind speed and direction, and potential temperature) is not reduced. In contrast, the LES technique can correct for shear and veer. In both cases, however, averaging the budget components shows no significant impact on the mean flow quantities in the microscale and is not necessary when coupling mesocale budget components to the LES model.

17 WIND ENERGY↗

DOE OSTI2021

Component-wise reduced order model lattice-type structure design

Lattice-type structures can provide a combination of stiffness with light weight that is desirable in a variety of applications. Design optimization of these structures must rely on approximations of the governing physics to render solution of a mathematical model feasible. In this paper, we propose a topology optimization (TO) formulation that approximates the governing physics using component-wise reduced order modeling as introduced in Huynh et al. (2013); Eftang and Patera (2013), which can reduce solution time by multiple orders of magnitude over a full-order finite element model while providing a relative error in the solution of 1%. In addition, the offline training data set from such component-wise models is reusable, allowing its application to many design problems for only the cost of a single offline training phase, and the component-wise method is nearly embarrassingly parallel. We also show how the parameterization chosen in our optimization allows a simplification of the component-wise reduced order model (CWROM) not noted in previous literature, for further speedup of the optimization process. Furthermore, the sensitivity of the compliance with respect to the particular parameterization is derived solely at the component level. In numerical examples, we demonstrate a 1000x speedup over a full-order FEM model with relative error of 1% and show minimum compliance designs for two different cantilever beam examples, one smaller and one larger. Finally, error bounds for the displacement field, compliance, and compliance sensitivity of the CWROM are derived.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

On component isolation of conceptual advanced reactors

Implementation of component isolation in nuclear industry is challenging due to gaps in research and the lack of specific guidelines. In this study, parameters affecting component-level isolation of advanced reactor vessels are identified based on a representative numerical model with explicit consideration of nonlinear soil-structure interaction (SSI). The objective of this study is to evaluate the effectiveness of, and to identify potential limitations of using conventional friction pendulum and lead-rubber bearings to seismically isolate vessels. It is found that slender vessels or components are particularly vulnerable to rotational accelerations at the isolation interface, which are caused by rotation of the sub-structure and by excitation of higher modes in the horizontal direction of the seismically isolated system. Component isolation is found to be more effective for relatively stiffer vessels and at sites with stiff soil properties. Considering that conventional isolators are deficient in resisting axial tension, it is observed that the optimum location for supporting a component to achieve seismic isolation, is at a cross-sectional plane passing through the center of mass of the vessel. These findings are corroborated by numerous simulations of the response of seismically isolated reactor vessels at different nuclear sites subject to a variety of ground motions.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Proposed Application for an Entity Component System in an Energy Services Interface

An Entity Component System is a data-oriented architecture originally developed to streamline video game performance. Despite being quite new, Entity Component Systems are relatively well established within the video game industry due to the cutting edge nature of research into performance, especially around graphics. However, Entity Component Systems have not been widely examined or adopted outside of that industry. We propose adopting an Entity Component Systems framework to serve the needs of an Energy Service Interfaces. We examine the needs of an Energy Service Interface, give an overview of open-source Entity Component Systems (ECSs) libraries, examine some preliminary performance results for ECSs, and explore the traditional approach to fulfilling the needs of an Energy Service Interface (ESI) with database architectures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Magnetic Gears for a Marine Hydrokinetic Generator Component Model

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). The Component Content Model provides data submitters with an easy and consistent means of uploading data and associated meta data about a component that is currently under development. The data fields include generic information about the component, technology classifications, current costs and performance, proposed target goals, and the environment that the component is operated in. These data are important to DOE and will be used to develop data products that provide quantitative information to guide and support programmatic decisions. Data will also be used by DOE in general assessments of MHK component readiness, performance, costs, and proposed plans. The ultimate goal is to use these data to perform research and tailor programs to best benefit the industry.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Isolation and conversion of electrolyte components into a value-added product

The overall objective of this work was to develop a process for effectively (i) recycling the electrolyte components from the end-of-life batteries and reduce the environmental hazard, (ii) understand the fundamental differences between pristine and recycled electrolyte components, (iii) electrochemically and analytically evaluate the recycled electrolyte components and (iv) establish deviations from the pristine electrolyte, and effectively separation of value-added product. We focused on determining scaling up the electrolyte recovery process by distillation of end-of-life batteries to get yield enough to use it for electrolyte formulation of reuse in the battery cell. The used cells from the ORNL battery manufacture facility (BMF)as well as received from the industry partner, Austin Elements Inc., was scaled to 10 used multilayered pouch cells in each batch of distillation and systematically separated and identified the electrolyte components of the used cells with FTIR and NMR studies. We were able to recovery 10g of solvent mass from the used pouch cells. NMR spectroscopy showed that the solvent was pure EMC,DMC and the sample was used to make a new battery cell. The end-of-life battery, it was noted that some cells were visually drier than the other cells and were more advanced in aged. In that case, even though the same distillation conditions were utilized, no usable mass of electrolyte solvent was recovered. It is expected that most of the solvent was decomposed during the battery charge-discharge cycling. The solid salt residue was separated by chemical and water treatment processes. Components of resulting solid product was analyzed by XRD and XPS measurements. The solid products are very much related to the salts used in the electrolyte solution.

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 OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Alternating chempolishing and electropolishing for interior and exterior surface finishing of additively manufactured (AM) metal components

Additively manufactured (AM) components’ surface finishing is crucial in adopting them for intended applications in challenging environments involving fatigue, corrosion, high temperature, and nuclear radiation. In our prior research, chempolishing (C) was utilized as an electroless etching process that uniformly smoothens complex AM components’ accessible interior and exterior surfaces (Tyagi et al. Additive Manufacturing, 25:32–38, 22). A wide range of electropolishing (E) has been demonstrated for AM surface finishing. However, electropolishing can impact a surface that can be juxtaposed to counter electrode and can yield a very smooth surface to sub-micrometer level roughness. However, a knowledge gap exists about the impact of applying both approaches on the same surface one after another and what new advantages may arise because of combining two methods. This paper uses dual-stage liquid-based surface finishing strategies produced by alternating the chempolishing (C) and electropolishing (E) steps. Two dual-stage surface finishing approaches, i.e., chempolishing followed by electropolishing (CE) and electropolishing followed by chempolishing (EC), were performed on the 316 stainless AM steel component. Impacts of EC and CE approaches were compared with single-stage C and E surface finishing approaches. An optical microscope and mechanical profilometer were utilized to investigate the wide range of surface roughness parameters. CE and EC produced Ra ~ 1.4 µm and ~ 1.6 µm, respectively. Surface roughness on CE- and EC-treated AM samples was lower than those individually treated by C and E approaches. Scanning electron microscopy provided further insights into the microstructural difference between CE- and EC-treated AM samples. This paper reports a liquid contact angle study on CE- and EC-treated AM samples to provide insights into the relative difference in surface energy that is crucial for making coatings on AM parts. A spectroscopic reflectance study was also employed to register the difference in physical properties of AM components treated with CE and EC approaches. Further, this study reveals industrially practicable interior and exterior surface finishing approaches for complex AM metal components that require minimum tooling and real-time process monitoring.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Embedding ceramic components in metal structures with hybrid directed energy deposition

The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including (1) to create complex interwoven ductile/brittle composites for ballistics or high-temperature applications or (2) to integrate high-temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. Here, in this work, stainless steel substrates were machined to create an internal cavity for the insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted, and different process sequences were allowed to continue to envelop the inserted ceramic with varying success. Unmelted powder was used to serve both as a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet). The wet powder has previously been demonstrated to not significantly impact the mechanical properties of a final structure and provided a thermal barrier to protect the ceramic piece from the extreme temperatures of the final metal deposition. The wetting of the powder provided stability and minimized displacement caused by the powder flow from the laser cladding head. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic component and, consequently, improved the survival of the ceramic inserts. With this combination of techniques, ceramic inserts survived full embedding within a 3D-printed stainless steel structure.

36 MATERIALS SCIENCE↗