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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 109 records · Page 6

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

Variability and associated uncertainty in image analysis for soiling characterization in solar energy systems

The accumulation of soiling on photovoltaic modules and on the mirrors of concentrating solar power systems causes non-negligible energy losses with economic consequences. These challenges can be mitigated, or even prevented, through appropriate actions if the magnitude of soiling is known. Particle counting analysis is a common procedure to characterize soiling, as it can be easily performed on micrographs of glass coupons or solar devices that have been exposed to the environment. Particle counting does not, however, yield invariant results across institutions. The particle size distribution analysis is affected by the operator of the image analysis software and the methodology utilized. The results of a round-robin study are presented in this work to explore and elucidate the uncertainty related to particle counting and its effect on the characterization of the soiling of glass surfaces used in solar energy conversion systems. An international group of soiling experts analyzed the same 8 micrographs using the same open-source ImageJ software package. The variation in the particle analyses results were investigated to identify specimen characteristics with the lowest coefficient of variation (CV) and the least uncertainty among the various operators. The mean particle diameter showed the lowest CV among the investigated characteristics, whereas the number of particles exhibited the largest CV. Additional parameters, such as the fractional area coverage by particles and parameters related to the distribution's shape yielded intermediate CV values. These results can provide insights on the magnitude inter-lab variability and uncertainty for optical and microscope-based soiling monitoring and characterization.

14 SOLAR ENERGY↗

Some Protocols For Optical-Fiber Digital Communications

One works best in heavy traffic, another, in light traffic. Three protocols proposed for digital communications among stations connected by passive taps to pair of uni-directional optical-fiber buses. Mediate round-robin, bounded-delay access to buses by all stations and particularly suited to fast transmission. Partly because transmission medium passive (no relay stations) and partly because protocols distribute control of network among all stations with provision for addition and deletion of stations (no control stations), communication network able to resist and recover from failures. Implicit token propagates in one direction on one bus and in opposite direction on other bus, minimizing interval of silence between end of one round and beginning of next.

Yeh, Cavour↗

How Reproducible are Surface Areas Calculated from the BET Equation?

Abstract Porosity and surface area analysis play a prominent role in modern materials science. At the heart of this sits the Brunauer–Emmett–Teller (BET) theory, which has been a remarkably successful contribution to the field of materials science. The BET method was developed in the 1930s for open surfaces but is now the most widely used metric for the estimation of surface areas of micro‐ and mesoporous materials. Despite its widespread use, the calculation of BET surface areas causes a spread in reported areas, resulting in reproducibility problems in both academia and industry. To prove this, for this analysis, 18 already‐measured raw adsorption isotherms were provided to sixty‐one labs, who were asked to calculate the corresponding BET areas. This round‐robin exercise resulted in a wide range of values. Here, the reproducibility of BET area determination from identical isotherms is demonstrated to be a largely ignored issue, raising critical concerns over the reliability of reported BET areas. To solve this major issue, a new computational approach to accurately and systematically determine the BET area of nanoporous materials is developed. The software, called “BET surface identification” (BETSI), expands on the well‐known Rouquerol criteria and makes an unambiguous BET area assignment possible.

36 MATERIALS SCIENCE↗

Flexible User-Defined Domain Decomposition in Kilometer-Scale E3SM Land Model Simulation

The Energy Exascale Earth System Model (E3SM) Land Model (ELM) has been extended to kilometer-scale (km-ELM) resolutions, enabling high-fidelity simulations of terrestrial processes at 1 km x 1 km grid spacing. In ELM, domain decomposition partitions the computational domain across processors, ensuring efficient parallel execution. Currently, round-robin decomposition is applied, providing a straightforward way to distribute computational workload. As ELM continues evolving at the kilometer-scale (km-scale), particularly with integrating lateral flow modeling, decomposition strategies must also account for the increased workload and data movement. This paper introduces a flexible user-defined domain decomposition framework, allowing users to customize domain partitioning based on application requirements. The impact of different decomposition strategies is evaluated across various applications concerning computation, communication, and I/O. Results demonstrate that while 1D partitioning yields superior I/O performance, k-nearest neighbors (KNN) clustering effectively reduces inter-process communication overhead. This study lays the groundwork for scalable partitioning in large-scale land surface simulations, enhancing next-generation Earth system modeling.

Wang, Dali [ORNL] (ORCID:0000000168065108)↗

The Impact of Impurities on Alloy Behavior in Supercritical CO 2 at 700 °C

As part of round robin testing, specimens of commercial alloys 316, 120, 625, and 740 were exposed to 20 MPa research grade CO 2 at 700 °C for up to 1500 h. The first set of specimens had higher mass gain likely due to impurities not flushed from the autoclave at startup. After this issue was corrected, an identical set of specimens exhibited lower mass gains for both the Fe- and Ni-based alloys. The differences in reaction products were characterized to understand the effect of impurities under these conditions. As suggested by the mass change, thicker oxides were formed in each case, primarily for the Fe-based alloys. Furthermore, for the Ni-based alloys, the difference was primarily in the transient stage of oxidation with no change in rate constant. Alloy 120 exhibited increased internal attack, and differences in the scale phases formed were characterized to better understand the effect of impurities. Alloy 740 primarily exhibited a greater depth of internal attack in the first run.

36 MATERIALS SCIENCE↗

Comparison of EBSD, DIC, AFM, and ECCI for active slip system identification in deformed Ti-7Al

The use of SEM-DIC, AFM, ECCI, and HR-EBSD to characterize slip-system activity was assessed on the same material volume of Ti-7Al. This study presents a robust comparison of the various methods for the first time, including an assessment of their advantages and disadvantages, and how they can be used effectively in a complementary fashion. The analysis of the different approaches was carried out in a blind, round-robin manner at three different universities. A Ti-7Al specimen was deformed in uniaxial tension to approximately 3% axial strain, and the active slip systems were independently identified using (i) trace analysis; (ii) in-SEM digital image correlation, (iii) observations of residual dislocations from ECCI, and (iv) long-range rotation gradients through HR-EBSD, with consistent trace identification in all cases. Displacement data from AFM was used to augment SEM-DIC displacement data by providing complementary out-of-plane displacement information. Furthermore, short-range dislocation gradients (measured by DIC) provided insight into the residual geometrically necessary dislocation (GND) content, and was consistent with the GND content extracted from EBSD data and ECCI images, confirming the presence of residual GNDs on the dominant slip systems resulting in visible slip bands. Furthermore, these approaches can be used in tandem to provide multi-modal information on slip band identification, strain and orientation gradients, out-of-plane displacements, and the presence of GNDs and SSDs, all of which can be used to inform and validate the development of dislocation-based crystal plasticity and strain gradient models.

36 MATERIALS SCIENCE↗

Integrating crystallographic and computational approaches to carbon-capture materials for the mitigation of climate change

Here, this article presents an overview of the current state of the art in the structure determination of microporous carbon-capture materials, as discussed at the recent NIST workshop “Integrating Crystallographic and Computational Approaches to Carbon-Capture Materials for the Mitigation of Climate Change”. The continual rise in anthropogenic CO 2 concentration and its effect on climate change call for the implementation of carbon capture technologies to reduce the CO 2 concentration in the atmosphere. Porous solids, including metal–organic frameworks (MOFs), are feasible candidates for gas capture and storage applications. However, determining the structure of these materials represents a significant obstacle in their development into advanced sorbents. The existing difficulties can be overcome by integrating crystallographic methods and theoretical modeling. The workshop gathered experimentalists and theorists from academia, government, and industry to review this field and identify approaches, including collaborative opportunities, required to develop tools for rapid determination of the structures of porous solid sorbents and the effect of structure on the carbon capture performance. We highlight the findings of that workshop, especially in the need for reference materials, standardized procedures and reporting of sorbent activation and adsorption measurements, standardized reporting of theoretical calculations, and round-robin structure determination.

36 MATERIALS SCIENCE↗

Transverse thermal energy conversion using spin and topological structures

Conversion of thermal to electrical energy has been a subject of intense study for well over two centuries. Despite steady progress throughout the past several decades, solid-state thermoelectric (TE) energy conversion devices remain adequate only for niche applications. One appealing option for circumventing the limits of conventional TE physics is to utilize phenomena where flows of heat and charge are perpendicular, the so-called “transverse” geometry. In this Tutorial, we discuss recent advances behind new ways to generate large transverse thermoelectric voltages, such as the spin Seebeck and Nernst effects, as well as Weyl physics. We provide suggestions for how these mechanisms might be enhanced and implemented into high-efficiency, next generation transverse TE devices. Furthermore, we also discuss best practices for accurate measurement and reporting of transverse thermoelectric material properties, including a case study of a round robin spin Seebeck coefficient measurement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Coding the Computing Continuum: Fluid Function Execution in Heterogeneous Computing Environments

Advances in network technologies have greatly decreased barriers to accessing physically distributed computers. This newfound accessibility coincides with increasing hardware specialization, creating exciting new opportunities to dispatch workloads to the best resource for a specific purpose, rather than those that are closest or most easily accessible. We present Delta, a service designed to intelligently schedule function-based workloads across a distributed set of heterogeneous computing resources. Delta implements an extensible architecture in which different predictors and scheduling algorithms can be integrated to provide dynamically evolving estimates of function execution times on different resources-estimates that can be used to determine the most appropriate location for execution. We describe predictors for function runtime, data transfer time, and cold-start resource provisioning and configuration delay; dynamic learning methods that update predictor models over time; and scheduling strategies that take into account both function and endpoint information. We show that these methods can halve workload makespan when compared with a strategy that selects the fastest resource, and decrease makespan by a factor of five when compared to a round robin strategy, when deployed on a heterogeneous testbed with resources ranging from a Raspberry Pi to a GPU node in an academic cloud.

Computing continuum↗

A Custom High-Throughput Optical Mapping Instrument for Accelerated Stress Testing of PV Module Materials

The performance and integrity of photovoltaic (PV) modules and materials may be assessed through optical characterizations. We have developed a custom optical mapping instrument (OMI) to improve measurement throughput time, facilitate automated measurements, allow for localized specimen examination, obtain spatial information relative to commercial benchtop spectrophotometer instruments, and provide automated data analysis. Both the key components and the methods used to improve the measurements are described. The measurement precision for the OMI is benchmarked for hemispherical transmittance relative to a previous round-robin study for commercial spectrophotometers. In addition to the unique instrument developed in this study, new insights have emerged from the examination of specimens from previous experiments, including: the depletion of the UV absorber is revealed for specimens beyond a certain size after artificial ultraviolet (UV) weathering; an optical degradation by internal haze formation is confirmed following Damp Heat (85 °C/85% relative humidity) testing; the better uniformity of the wear pattern for falling sand abrasion is used to select the DIN 52348 fixture over the ASTM D968 fixture; and the greater local (in the order of millimeters) heterogeneity of surface contamination in the soiling-prone location of Dubai relative to Kuwait. The results of the UV study have already been used to improve the standardized weathering of encapsulants. The example for Damp Heat testing is given to increase awareness of a degradation believed to be ubiquitously occurring in safety and design-type qualification testing of PV modules.

14 SOLAR ENERGY↗

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. A recently proposed method to capture the rolling element bearing degradation provides the groundwork for new indicator families utilizing the generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the National Renewable Energy Laboratory Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox; hence the complexity of the vibration signals is similar to a real case. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗

Membrane Pretreatment and Cell Conditioning for Proton Exchange Membrane Water Electrolysis

As the research community studying proton exchange membrane water electrolysis (PEMWE) grows, it is important to develop methods that achieve transparent, reproducible research. Reproducibility of performance and durability is a challenge facing the PEMWE field, as the published literature includes a wide spread of results obtained with nominally similar materials. Prior round-robin performance benchmarking efforts [1] have identified inadequate cell conditioning as a major source of variation in apparent cell performance. Inadequate pre-treatment and conditioning can lead to instability in initial performance and adds ambiguity to durability measurements. However, excessively prolonged conditioning procedures limit the throughput of testing and the pace of research. Pretreatment and conditioning methods vary significantly across the research literature, but little systematic investigation is available into the mechanisms of these procedures or how procedural differences may impact results. This presentation will discuss investigations into the effects of membrane pre-treatment and operating procedures during cell conditioning on initial performance and catalyst-specific accelerated stress tests, with the aim of recommending procedures to enable clear, reproducible, and high-throughput research. Methods investigated include the use of hydrogen peroxide, acids, and hydration at elevated temperature for membrane pretreatment, and conditioning procedures such as current or voltage holds and cycling. The investigations cover both the impacts of these procedures on cell performance and stability as well as underlying mechanisms and processes taking place in the cell materials.

cell↗

Landmark Publications in Analytical Atomic Spectrometry: Fundamentals and Instrumentation Development

The almost-two-centuries history of spectrochemical analysis has generated a body of literature so vast that it has become nearly intractable for experts, much less for those wishing to enter the field. Authoritative, focused reviews help to address this problem but become so granular that the overall directions of the field are lost. This broader perspective can be provided partially by general overviews but then the thinking, experimental details, theoretical underpinnings, and instrumental innovations of the original work must be sacrificed. In the present compilation, this dilemma is overcome by assembling the most impactful publications in the area of analytical atomic spectrometry. Each entry was proposed by at least one current expert in the field and supported by a narrative that justifies its inclusion. The entries were then assembled into a coherent sequence and returned to contributors for a round-robin review. A total of 48 scientists participated in this endeavor, contributing a combined list of 1055 individual articles spanning 17 sub-disciplines of spectrochemical analysis into what the current community views as “key” publications. Of these cited articles, 60 received nominations from four or more scientists, establishing them as the most indispensable reading materials. The outcome of this collaborative effort is intended to serve as a valuable resource not only for current practitioners in atomic spectroscopy but also for present and future students who represent coming generations of analytical atomic spectroscopists.

Instruments & Instrumentation↗

Lamb wave imaging with actuator network for damage quantification in aluminum plate structures

Lamb waves have been widely used for damage detection on plate-like structures. However, there are still considerable interests on quantifying damage with complex profile. In this article, quantification of complex damage in plate-like structures using a network of actuators and time-space Lamb wavefield is investigated. The actuator network inspection system is implemented with multiple PZT transducers for Lamb wave actuation in round robin pattern and scanning laser Doppler vibrometer for wavefield sensing. The PZT network is arranged in a way that the target area is fully enclosed and Lamb waves come to the damage from all directions. Waves induced by the damage are subsequently obtained through frequency-wavenumber filtering, using the experimentally acquired dispersion curves presented in the paper. The filtered waves from all wave actuators are then used to generate a synthetic image of the damage being inspected. Two cases of complex damage are evaluated on aluminum plates, mass loss with triangular profile and mass addition with a three-letter cluster profile. Our results show that the damages are not only detected but also their profiles are clearly outlined in the images. We believe the subject methods provide improved evaluation of damage profile for Lamb wavefield based damage quantification.

Materials Science↗

Angle of Incidence Characterization of Six Laminated Solar Cells for 2020 DTU Fotonik Inter-Laboratory Comparison Study

Photovoltaic energy prediction models include functions or modifiers to account for sun angle reflection losses. These functions may be known interchangeably as Angle of Incidence (AOI) or Incident Angle Modifier (IAM). While standards exist, there is no universally accepted single best practice for developing these functions. They can be generated through characterization of representative modules or single cells, in natural sunlight or indoors using simulated light sources. Repeatability of measurements and the viability of cross-laboratory comparisons are critical to confidence in validation of both methods. To investigate the differences between methods and labs, The Technical University of Denmark (DTU) initiated an international round-robin test comparison between several key test labs with AOI measurement capability. A total of six minimodules were provided in three different cell/interconnect/backsheet combinations. Sandia characterized these minimodules using methods developed over two decades specifically for the outdoor characterization of full-size photovoltaic modules. This report documents the characterization results, summarizes key observations and tabulates the processed data for comparison to results provided by other characterization labs.

14 SOLAR ENERGY↗

Guidelines for IAEA Small Specimen Test Techniques Master Curve Fracture Toughness Testing

Under the auspices of International Atomic Energy Agency (IAEA), a coordinated research project (CRP) entitled “Towards the Standardization of Small Specimen Test Techniques for Fusion Applications” has started since 2017. The overall objective of the project is to provide a set of guidelines for small specimen test techniques (SSTT) based on commonly agreed best practices on main test techniques including tensile, creep, low cycle fatigue, fracture toughness, and fatigue crack growth rate. This will act as the first step of a full standardization of the SSTT. Fusion structural materials, i.e., reduced activation ferritic/martensitic (RAFM) steels, are used for testing. In addition, the project will create a comprehensive mechanical property database of RAFM steels tested by SSTT. For the fracture toughness task of the CRP, three testing methods including Master Curve, local approach for ductile crack growth and cleavage fracture, and ductile approach at room temperature will be evaluated. This report focuses on developing guidelines for the round-robin Master Curve testing based on the ASTM standard E1921-19b “Standard Test Method for Determination of Reference Temperature, T 0 , for Ferritic Steels in the Transition Range” and commonly agreed best practice from researchers at Oak Ridge National Laboratory (ORNL), Centre for Energy, Environment and Technology (CIEMAT), and UK Atomic Energy Authority (UKAEA).

36 MATERIALS SCIENCE↗

NWAL Validation Report for U Assay by Potentiometric Titration (Modified Davies and Gray Technique) and U and PU Assay by Isotope Dilution Mass Spectrometry

SRNL Sensing & Metrology, previously Analytical Laboratory, is a member of the IAEA Network of Analytical Laboratories for Nuclear Material Measurement that is qualified to provide Uranium and Plutonium isotopic analysis of nuclear materials by Thermal Ionization Mass Spectrometry. As part of the membership, SRNL participated in the 2019 Nuclear Material Round Robin to maintain the qualification to provide isotopic analysis. SRNL also participated with the additional intent to qualify Uranium Assay by Potentiometric Titration (Davies and Gray method) and Uranium and Plutonium Isotope Dilution by Thermal Ionization Mass Spectrometry as part of the International Atomic Energy Agency’s Network of Analytical Laboratories. The proficiency test exercise was conducted by the Office of Safeguards Analytical Services, Department of Safeguards.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗