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DOE OSTI2023

Fulcrum House – Towards a Sustainable Composite Architecture

In the last decades, the accessibility to digital fabrication technologies positioned composites as an affordable, structurally efficient and low-maintenance alternative to traditional mineral-based and high-energy materials. Of special interest are carbon nanotubes (CNT) and carbon foam (CFoam) from methane and coal pyrolysis respectively, as an environmentally friendly substitute to glass and carbon fiber. This paper presents the design of a principled single-family house, as a first case study to identify the constraints of such a material system, including technology gap, techno-economic and life cycle assessment, as well as building code requirements. In turn, the investigation proposes a suitable design-to-fabrication workflow, which potentially could bring CNT and CFoam materials to the construction of buildings.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1979

An economic analysis of a commercial approach to the design and fabrication of a space power system

This paper discusses a commercial approach to the design and fabrication of an economical space power system. With the advent of the space shuttle, steps can be taken to back away from the presently used space qualified approach in order to reduce cost of space hardware by incorporating, where possible, commercial design, fabrication, and quality assurance methods. Cost reductions are projected through the conceptual design of a 2 kW space power system built with the capability for having serviceability. The approach to system costing that has been used takes into account both the constraints of operation in space and commercial production engineering approaches. The cost of this power system reflects a variety of cost/benefit tradeoffs that would reduce system cost as a function of system reliability requirements, complexity, and the impact of rigid specifications. A breakdown of the system design, documentation, fabrication and reliability and quality assurance cost estimates are detailed.

Putney, Z.↗

DOE OSTI2023

Limited-constraint WAAM fixture for hybrid manufacturing

This paper describes a limited-constraint alternative to the traditional over-constrained build plate clamping in metal additive manufacturing. A fixture design is presented that enables build plate thermal growth within its plane while restricting deformation perpendicular to that plane. A prototype fixture is designed, fabricated, and tested for wire arc additive manufacturing (WAAM). Experimental results are presented for depositing 1.2 mm diameter 5356 aluminum wire on a 5052 aluminum build plate. The build plate deformation is measured for various clamping torques and a 77.3% reduction in distortion is achieved using the limited-constraint approach with identical WAAM parameters.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Documentation of Stainless Steel Lithium Circuit Test Section Design

The Early Flight Fission-Test Facilities (EFF-TF) team was tasked by Naval Reactors Prime Contract Team (NRPCT) to design, fabricate, and test an actively pumped lithium (Li) flow circuit. This Li circuit takes advantage of work in progress at the EFF TF on a stainless steel sodium/potassium (NaK) circuit. The effort involved modifying the original stainless steel NaK circuit such that it could be operated with Li in place of NaK. This new design considered freeze/thaw issues and required the addition of an expansion tank and expansion/extrusion volumes in the circuit plumbing. Instrumentation has been specified for Li and circuit heaters have been placed throughout the design to ensure adequate operational temperatures and no uncontrolled freezing of the Li. All major components have been designed and fabricated prior to circuit redesign for Li and were not modified. Basic circuit components include: reactor segment, Li to gas heat exchanger, electromagnetic liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and trace heaters. The reactor segment, based on a Los Alamos National Laboratory 100-kW design study with 120 fuel pins, is the only prototypic component in the circuit. However, due to earlier funding constraints, a 37-pin partial-array of the core, including the central three rings of fuel pins (pin and flow path dimensions are the same as those in the full design), was selected for fabrication and test. This Technical Publication summarizes the design and integration of the pumped liquid metal Li flow circuit as of May 1, 2005.

Godfroy, T. J.↗

NASA NTRS2010

Documentation of Stainless Steel Lithium Circuit Test Section Design

Godfroy, Thomas J.↗

NASA NTRS1979

An economic analysis of a commercial approach to the design and fabrication of a space power system

A commercial approach to the design and fabrication of an economical space power system is presented. Cost reductions are projected through the conceptual design of a 2 kW space power system built with the capability for having serviceability. The approach to system costing that is used takes into account both the constraints of operation in space and commercial production engineering approaches. The cost of this power system reflects a variety of cost/benefit tradeoffs that would reduce system cost as a function of system reliability requirements, complexity, and the impact of rigid specifications. A breakdown of the system design, documentation, fabrication, and reliability and quality assurance cost estimates are detailed.

Putney, Z.↗

DOE OSTI2021

From Materials to Cell: State-of-the-Art and Prospective Technologies for Lithium-Ion Battery Electrode Processing

Electrode processing plays an important role in advancing lithium-ion battery technologies and has a significant impact on cell energy density, manufacturing cost, and throughput. Compared to the extensive research on materials development, however, there has been much less effort in this area. In this Review, we outline each step in the electrode processing of lithium-ion batteries from materials to cell assembly, summarize the recent progress in individual steps, deconvolute the interplays between those steps, discuss the underlying constraints, and share some prospective technologies. Finally, this Review aims to provide an overview of the whole process in lithium-ion battery fabrication from powder to cell formation and bridge the gap between academic development and industrial manufacturing.

25 ENERGY STORAGE↗

DOE OSTI2022

Mineralogy, fabric and deformation domains in D" across the southwestern border of the African LLSVP

Recent advances in seismic anisotropy studies that jointly use reflections and shear wave splitting have proven to place tight constraints on the plausible anisotropic and deformation scenarios in the D" region. We apply this novel methodology to a large area of the D" region beneath the South Atlantic, in proximity to and within the African large low seismic velocity province (LLSVP). This area of the mantle is characterized by a transition from fast to slow seismic velocity anomalies and it is thought to be the location of deep-seated plumes responsible for hotspot volcanism. Attempting to probe mantle composition and deformation along the LLSVP borders may provide key information on mantle dynamics. By analysing seismic phases sampling this region, we detect a D" discontinuity over a large area beneath the South Atlantic, with inferred depth ranges ~170 to ~240 km above the core–mantle boundary. We find evidence for a D" reflector within the area of the LLSVP. Shear wave splitting observations suggest that anisotropy is present in this region of the mantle, in agreement with previous studies that partially sampled this region. We model the observations considering lattice- and shape-preferred orientation of materials expected in the D" region. A regional variation of mineralogy, phase transition boundaries, and deformation direction is required to explain the data. We infer two distinct domains of mineralogy and deformation: aligned post-perovskite outside the LLSVP and aligned bridgmanite within the LLSVP. Finally, the scenario depicted by this study agrees well with the current hypotheses for the composition of the LLSVP and with the prevalence of vertical deformation directions expected to occur along the LLSVPs borders.

58 GEOSCIENCES↗

DOE OSTI2020

Design Principles to Govern Electrode Fabrication for the Lithium Trivanadate Cathode

A full depth of discharge mathematical model for the lithium trivanadate cathode, considering lithiation of the layered α-phase, phase change, and lithiation of the rock-salt like β-phase at lower potentials, is developed. The coupled electrode-scale and crystal-scale model is fit to electrochemical data, and additionally validated with operando EDXRD. There is good agreement between the simulated and measured spatial variation of the volume fraction of the β-phase. This mathematical model is used to guide electrode fabrication, accounting for both ionic and electronic transport effects. Values of three design parameters—electrode thickness, porosity, and volume fraction of conductor—are identified, and the sensitivity of the energy density to these design parameters is quantified. The model is also used to investigate electrode design to create electrodes that deliver the maximum achievable energy density under the constraint that the α to β-phase transition is avoided, since phase change has been demonstrated to reduce cycle life. The energy density sacrificed to avoid phase change decreases at higher discharge rates, but the target values for electrode fabrication remain the same as those when optimizing the electrode for the full depth of discharge.

25 ENERGY STORAGE↗

NASA NTRS2005

Net-Shape HIP Powder Metallurgy Components for Rocket Engines

True net shape consolidation of powder metal (PM) by hot isostatic pressing (HIP) provides opportunities for many cost, performance and life benefits over conventional fabrication processes for large rocket engine structures. Various forms of selectively net-shape PM have been around for thirty years or so. However, it is only recently that major applications have been pursued for rocket engine hardware fabricated in the United States. The method employs sacrificial metallic tooling (HIP capsule and shaped inserts), which is removed from the part after HIP consolidation of the powder, by selective acid dissolution. Full exploitation of net-shape PM requires innovative approaches in both component design and materials and processing details. The benefits include: uniform and homogeneous microstructure with no porosity, irrespective of component shape and size; elimination of welds and the associated quality and life limitations; removal of traditional producibility constraints on design freedom, such as forgeability and machinability, and scale-up to very large, monolithic parts, limited only by the size of existing HIP furnaces. Net-shape PM HIP also enables fabrication of complex configurations providing additional, unique functionalities. The progress made in these areas will be described. Then critical aspects of the technology that still require significant further development and maturation will be discussed from the perspective of an engine systems builder and end-user of the technology.

Bampton, Cliff↗

NASA NTRS2020

Evaluation of Packing_3D Code for Design of Variable-Depth, Bent-Chamber Acoustic Liners

Increases in the bypass ratio for commercial aircraft engines have caused the broadband fan noise component to become dominant. As a result, there is a need to develop improved acoustic liners suitable for absorption of this fan noise over a wide frequency range, preferably up to at least two octaves. Variable depth liners with bent chambers and three-dimensional geometries present one way to achieve this goal, however, they can be difficult and time-consuming to design due to their complexity and volume constraints. A packing code, called Packing3D, has been developed that automatically designs the chamber configurations of such liners once the chamber dimensions and volume constraints are known. The code uses a randomized trial and error approach to place each chamber in a representation of the liner sample, then returns a colored diagram and sufficient information for the liner sample to be fabricated. For evaluation, the code is used to design four liner samples of varying levels of complexity. These samples are tested with and without a mesh facesheet in the NASA Langley Normal Incidence Tube, and the results are compared to predictions computed in COMSOL. The results indicate that the packing code is able to quickly design samples that are predictable, achieve the desired absorption spectrum, fit the given constraints, and are able to be built. This code is flexible, lends itself to optimization, and allows samples to be designed quickly, accurately, and efficiently.

Marinova, Miroslava M.↗

NASA NTRS2016

Space to Space Advanced EMU Radio

The main task for this project was the development of a prototype for the Space to Space Advanced EMU Radio (SSAER). The SSAER is an updated version of the Space to Space EMU Radio (SSER), which is the current radio used by EMUs (Extravehicular Mobility Unit) for communication between suits and with the ISS. The SSER was developed in 1999, and it was desired to update the design used in the system. Importantly, besides replacing out-of-production parts it was necessary to decrease the size of the radio due to increased volume constraints with the updated Portable Life Support System (PLSS) 2.5, which will be attached on future space suits. In particular, it was desired to fabricate a PCB for the front-end of the prototype SSAER system. Once this board was manufactured and all parts assembled, it could then be tested for quality of operation as well as compliancy with the SSER required specifications. Upon arrival, a small outline of the target system was provided, and it was my responsibility to take that outline to a finished, testable board. This board would include several stages, including frequency mixing, amplification, modulation, demodulation, and handled both the transmit and receive lines of the radio. I developed a new design based on the old SSER system and the outline provided to me, and found parts to fit the tasks in my design. It was also important to consider the specifications of the SSER, which included the system noise figure, gain, and power consumption. Further, all parts needed to be impedance matched, and spurious signals needed to be avoided. In order to fulfill these two requirements, it was necessary to perform some calculations using a Smith Chart and excel analysis. Once all parts were selected, I drew the schematics for the system in Altium Designer. This included developing schematic symbols, as well as layout. Once the schematic was finished, it was then necessary to lay the parts out onto a PCB using Altium. Similar to the schematic design, in order to accomplish this it was necessary to develop component land patterns and add component 3D models. All of this was achieved, and the PCB is currently in review. After it is finished being reviewed, this board will be sent out for manufacture. All electronic components used in the PCB have been acquired, and once the board arrives they will be soldered onto the board using a machine in building 44. Finally, the board will be tested for performance on-site. This will likely be accomplished by the end of the internship.

Maicke, Andrew↗

DOE OSTI2023

High-bandwidth density silicon photonic resonators for energy-efficient optical interconnects

The growth of artificial intelligence applications demands ever larger and more complex deep learning models, dominating today's—and tomorrow's—data center and high-performance computing systems. While traditional electronics are failing to keep pace with application demands, silicon photonic (SiPh) interconnects have emerged as a necessary technology to support these systems. SiPh-driven wavelength-division multiplexing (WDM) offers a particularly promising path toward supporting incredibly high-aggregate link bandwidth in a compact and efficient form factor. One of the basic building blocks of these integrated WDM interconnects is the SiPh resonator. Their inherent wavelength selectivity and compact footprint allow for efficient data transmission multiplexed across dozens of carrier wavelengths. Used as add-drop (AD) filters, SiPh resonators are critical to constructing integrated tunable wavelength-selective optical circuit switches as well as for demultiplexing the different carrier wavelengths toward independent wavelength-insensitive photodiodes in a dense wavelength-division multiplexing receiver. Resonators in the all-pass (AP) configuration are widespread as well, allowing for wavelength-selective modulation to drive aggregate link bandwidths far beyond the individual channel data rate. Unlike SiPh Mach–Zehnder modulators (MZM), resonant modulators can be driven using low, complementary metal-oxide-semiconductor drive voltages, allowing for tight co-integration between photonic integrated circuits, fabricated with larger process node technologies, and electronic integrated circuits, designed to exploit the advantages of the latest node. To push toward practical peta-scale interconnects, a comprehensive review of SiPh resonators is required, addressing bottlenecks and design constraints at both the architecture and device levels. We first describe the predominant integrated link architectures and identify their limits. We then discuss the device-level design considerations that can be made for both AD and AP configuration resonators to overcome the system level limits with novel resonator device designs. Analytical models and numerical simulation of resonators are validated by experimental measurement of devices fabricated in a commercial 300-mm foundry, showing a clear path toward volume manufacturing. The demonstrated resonant modulators and filters support the feasibility of increasing the aggregate bandwidth of resonator-driven SiPh interconnects into the peta-scale regime.

42 ENGINEERING↗

NASA NTRS1995

Sample acquisition and instrument deployment

Progress is reported in developing the Sample Acquisition and Instrument Deployment (SAID) system, a robotic system for deploying science instruments and acquiring samples for analysis. The system is a conventional four degree of freedom manipulator 2 meters in length. A baseline design has been achieved through analysis and trade studies. The design considers environmental operating conditions on the surface of Mars, as well as volume constraints on proposed Mars landers. Control issues have also been studied, and simulations of joint and tip movements have been performed. The systems have been fabricated and tested in environmental chambers, as well as soil testing and robotic control testing.

Boyd, Robert C.↗

DOE OSTI2021

Markets and Economic Requirements for Fission Batteries and Other Nuclear Systems

Fission Batteries (FBs) are nuclear reactors defined by five characteristics which enable large-scale deployment: cost competitive, standardized sizes for economic mass production, easy installation and removal, secure and safe unattended operation with high reliability. FBs are not defined by technology or power level. Technical and market considerations suggest that most FBs will produce 20 to 30 MWt. This proceedings reports on the outcomes of two workshops that were held in January 2021 to better define markets and economic challenges for FBs. Three major markets were identified. The largest market is the industrial and commercial heat market. There are about 4000 industrial users (excluding utilities) that require more than one megawatt of heat. The number of customers versus size of heat demand was determined. In a low-carbon world there is the potential for many additional customers—including expanded biofuels production and district heat. The second market is for non-grid electricity. This includes co-generation plants that produce heat and electricity for a single customer. The third market is the maritime market with ~100,000 ships worldwide. In the United States, natural gas is the low-cost energy option today and will remain so unless constraints or taxes impact its use. If restrictions on greenhouse gas emissions, the FB competition includes natural gas with carbon capture, biofuels, hydrogen and grid electricity. Natural gas with carbon capture is not economically viable on a small scale. Biofuels may be expensive but may be the economically preferred option for locations with small energy demands of a few megawatts. Hydrogen is a potential competitor with many of the characteristics of natural gas. Grid electricity is not a competitive source of heat. For FBs to be economically competitive, the price of delivered heat must be $20-50/MWh ($6-15/million BTU). The economically competitive range for non-grid electricity is estimated at $70-100/MWh. These electricity prices are competitive with the retail prices of electricity in many parts of the United States for the customer. FBs are not expected to be competitive selling wholesale electricity to the grid. To achieve the aforementioned cost targets for heat and electricity markets, FB designers must (1) maximize the power output within the constraints of a FB (e.g., truck transportability, passive decay heat removal), (2) drastically reduce the size of onsite staff, (3) adopt core designs with low fuel costs (enrichment and fabrication), and (4) develop a system design that is efficiently manufactured in factories. The business case depends upon more than being just a replacement for natural gas. The largest incentives for adoption of FBs is where they create new markets and new sources of revenue. An example is the paper and pulp industry that burns biomass wastes to provide heat and electricity to make paper. An external heat source could meet the demand for heat and electricity by the paper process and enable converting waste biomass into liquid biofuels rather than burning to provide heat. Other markets, such as data centers, are driven by special energy requirements such as extreme reliability. Most customers are not in the energy business but need heat and electricity to produce a product—a manufactured good, education, retail sales (shopping malls), marine transport or some other product. As a consequence, there will be large incentives to lease rather than own FBs. Leasing avoids the regulatory challenges that remain with the owner of the FB. Leasing creates large incentives for FP standardization of sizes and transportability to maintain the value of the FB at the end of the lease—similar to the leasing of jet engines and aircraft. The economic constraints combined with technical constraints suggest competitive FBs will likely have outputs exceeding 10 MWt. There appear to be little incentives for very long-lived reactor cores because such machines require much larger inventories of fuel. Maintenance requirements and the options to provide technology updates may favor shorter lifetimes (~5 years). The assessment is that there is the potential for FBs to be economically viable and play a major role in global decarbonization in three markets: heat, non-grid electricity and maritime applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1970

Hypersonic research engine project. Phase 2: Structures and cooling development

The flightweight components were adapted to form the basic engine assembly. The water cooled test adapters for use in wind tunnel tests were fabricated. Commercially available valves were selected for the coolant control system. The simplification of the temperature control concept and of the absence of weight and volume constraints made it possible to use these valves. Various calibration tests are also discussed.

Jilly, L. F.↗

NASA NTRS1976

Space-to-earth power transmission system

A preliminary analysis was conducted to establish the requirements of a space-to-earth microwave power transmission system. The need for accurate phase control on the transmitter was established and methods for assessing the impact of power density and thermal constraints on system performance were demonstrated. Potential radio frequency interference was considered. The sensitivity of transmission system scale to variations in power source, transportation and orbital fabrication and assembly costs was also determined.

Stevens, G. H.↗

NASA NTRS2005

Thin Films and Inflatable Applications in Exploration Habitat Structures

NASA's vision to return to the Moon and then extend human exploration to Mars will benefit from human habitat technology development using new and creative applications of polymer materials and concepts. Thin Film and Inflatable (TFVI) materials are particularly interesting for exploration applications due to their light weight and low volume. Whereas TF/I materials can be launched and carried from Earth to multiple and distant exploration sites without the constraints of upmass limitations, eventually, with recycling and reclamation efforts, these materials may be developed using in-situ resources. These materials can be useful for fabricating, patching and repairing vehicles, replacement parts and even habitat structures, as well as for developing stand-alone habitat structure technologies and for nested and integrated applications. TF/Is can also be ideal environmental containment vessels within lunar or Martian regolith walls or as liners inside caves or raw regolith exterior structures for the provisions of atmosphere containment, debris protection and cleanliness. Further, TFOs can be specialized and matured for various and diverse applications. The desired range of applications will require materials specification for such properties as transparency, elasticity, thermal conductivity, mechanical strength, heat capacity, chemical resistance, and permeability. This paper will discuss Marshall Space Flight Center's plans to analyze and prioritize TF/I materials properties and classifications and to develop applications for these highly desirable materials in human habitat construction projects on the Moon and Mars.

Frazier, Donald O.↗