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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Relationship between clay minerals and microorganisms in underground hydrogen storage reservoirs: a mini review

Hydrogen (H 2 ) will play a vital role in the global shift towards sustainable energy systems. Due to the high cost and challenges associated with storing hydrogen in large quantities for industrial applications, Underground Hydrogen Storage (UHS) in geological formations has emerged as a promising solution. Clay minerals, abundant in subsurface environments, play a critical role in UHS by providing low permeability, cation exchange capacity, and stability, essential for preventing hydrogen leakage. However, microorganisms in the subsurface, particularly hydrogenotrophic species, interact with clay minerals in ways that can affect the integrity of these storage systems. Microbes form biofilms on clay surfaces, which can cause pore clogging and reduce the permeability of the reservoir, potentially stabilizing H 2 storage and limiting injectivity. Microbial-induced chemical weathering, through the production of organic acids and redox reactions, can degrade clay minerals, releasing metal ions and destabilizing the storage site. These interactions raise concerns about the long-term storage capacity of UHS, as microbial processes could lead to H 2 loss and caprock degradation, compromising the storage system’s effectiveness. This mini review aims to cover the current understanding of the interactions between clay minerals and microorganisms and how these dynamics can affect the safe and sustainable deployment of UHS .

Clark, Allison↗
DOE OSTI2023

Pore-Scale Analysis of the Permeability Damage and Recovery during Cyclic Freshwater and Brine Injection in Porous Media Containing Non-Swelling Clays

Permeability damage in subsurface porous media caused by clay mobilization is encountered in many engineering applications, such as geothermal energy, water disposal, oil recovery, and underground CO2 storage. During the freshwater injection into rocks containing brine, the sudden decrease in salinity causes native clay fines to detach and clog pore throats, leading to a significant decline in permeability. The clay fines detach due to weakened net-attractive forces binding them to each other and the grain. Past experiments link this permeability damage on the immediate history of the salinity and the direction of flow. To better understand this phenomenon, we conducted pore-scale simulations of cyclic injection of freshwater and brine into sandstone containing Kaolinite clay. Our simulations establish a link between the clay-fine trajectory and the permeability trend observed by Khilar and Fogler (1983). For a uniform clay size of 3 microns, we observe a permeability decline by two orders of magnitude during freshwater injection with respect to brine injection. Increasing salinity and simultaneously reversing flow direction restores the permeability. The permeability restoration upon reversing the brine flow direction is attributed to the unblocking of pore throats in the reverse direction by the movement of the clay particles along the grain surfaces by the hydrodynamic force and the strong net-attractive force under high salinity.

Bhuvankar, Pramod (ORCID:000000027739973X)↗
DOE OSTI2024

Mineral Deposition on the Rough Walls of a Fracture

Modeling carbonate growth in fractures and pores is important for understanding carbon sequestration in the environment or when supersaturated solutions are injected into rocks. Here, we study the simple but nontrivial problem of calcite growth on fractures with rough walls of the same mineral using kinetic Monte Carlo simulations of attachment and detachment of molecules and scaling approaches. First, we consider wedge-shaped fracture walls whose upper terraces are in the same low-energy planes and show that the valleys are slowly filled by the propagation of parallel monolayer steps in the wedge sides. The growth ceases when the walls reach these low-energy configurations so that a gap between the walls may not be filled. Second, we consider fracture walls with equally separated monolayer steps (vicinal surfaces with roughness below 1 nm) and show that growth by step propagation will eventually clog the fracture gap. In both cases, scaling approaches predict the times to attain the final configurations as a function of the initial geometry and the step-propagation velocity, which is set by the saturation index. The same reasoning applied to a random wall geometry shows that step propagation leads to lateral filling of surface valleys until the wall reaches the low-energy crystalline plane that has the smallest initial density of molecules. Thus, the final configurations of the fracture walls are much more sensitive to the crystallography than to the roughness or the local curvature. The framework developed here may be used to determine those configurations, the times to reach them, and the mass of deposited mineral. Effects of transport limitations are discussed when the fracture gap is significantly narrowed.

calcite↗
DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗
DOE OSTI2024

Long-Term Performance of Ag/AgCl Reference Electrodes for Corrosion Potential Monitoring in Radioactive Tank Waste at the Hanford Site

This work studied the exposure effects of radioactive tank waste on the long-term performance of single junction Ag/AgCl reference electrodes for corrosion potential monitoring at the Hanford Site. Electrodes from three manufacturers with very different designs were studied using open-circuit potential and electrochemical impedance measurements in radioactive tank waste. Post-test analyses were conducted on some failed electrodes using destructive and nondestructive techniques. The intrusion of the aggressive and radioactive chemicals in tank waste through the porous frit materials was the primary mechanism that led to the clogging of frit, physical and chemical degradation of AgCl bonded to Ag wire, and alteration of the internal electrolyte. Radiolytic chemical species such as H2O2 and HNO3 may have also induced the degradation of the Ag wire. The extent of electrode degradation and failure probability highly depended on the electrode design and environmental conditions. Chemicals in tank waste had stronger effects than radiation on the long-term performance of the Ag/AgCl reference electrodes.

Materials Science↗
NASA NTRS1970

Adjustable flow restrictor

Flow-rate restrictor with sharp-edged threads generates turbulence in the fluid flow, providing greater pressure reduction than is possible with a smooth-walled device. It is less susceptible to clogging.

Tufte, R. J.↗
NASA NTRS1971

Development of the activated diffusion brazing process for fabrication of finned shell to strut turbine blades

The activated diffusion brazing process was developed for attaching TD-NiCr and U700 finned airfoil shells to matching Rene 80 struts obstructing the finned cooling passageways. Creep forming the finned shells to struts in combination with precise preplacement of brazing alloy resulted in consistently sound joints, free of cooling passageway clogging. Extensive tensile and stress rupture testing of several joint orientation at several temperatures provided a critical assessment of joint integrity of both material combinations. Trial blades of each material combination were fabricated followed by destructive metallographic examination which verified high joint integrity.

Wilbers, L. G.↗
NASA NTRS1971

Radioactive nondestructive test method

Various radioisotope techniques were used as diagnostic tools for determining the performance of spacecraft propulsion feed system elements. Applications were studied in four tasks. The first two required experimental testing involving the propellant liquid oxygen difluoride (OF2): the neutron activation analysis of dissolved or suspended metals, and the use of radioactive tracers to evaluate the probability of constrictions in passive components (orifices and filters) becoming clogged by matter dissolved or suspended in the OF2. The other tasks were an appraisal of the applicability of radioisotope techniques to problems arising from the exposure of components to liquid/gas combinations, and an assessment of the applicability of the techniques to other propellants.

Obrien, J. R.↗
NASA NTRS1972

Material Compatibility with Space Storable Propellants. Design Guidebook

An important consideration in the design of spacecraft for interplanetary missions is the compatibility of storage materials with the propellants. Serious problems can arise because many propellants are either extremely reactive or subject to catalytic decomposition, making the selection of proper materials of construction for propellant containment and control a critical requirement for the long-life applications. To aid in selecting materials and designing and evaluating various propulsion subsystems, available information on the compatibility of spacecraft materials with propellants of interest was compiled from literature searches and personal contacts. The compatibility of both metals and nonmetals with hydrazine, monomethyl hydrazine, nitrated hydrazine, and diborance fuels and nitrogen tetroxide, fluorine, oxygen difluoride, and Flox oxidizers was surveyed. These fuels and oxidizers encompass the wide variety of problems encountered in propellant storage. As such, they present worst case situations of the propellant affecting the material and the material affecting the propellant. This includes material attack, propellant decomposition, and the formation of clogging materials.

Uney, P. E.↗
NASA NTRS1973

Characteristics of a gelled liquid hyprogen polyphenylene oxide (PPO) foam open-cell insulation system, phase 1

A large scale gel production and storage facility and a small scale facility, the latter used for detailed visual examination of the gel/PPO foam interface, were developed. A subcontract was given to investigate techniques for the production of gelled liquid hydrogen, develop a process design for scale-up to a 1.89 cu m (500 gallon) gel production and storage facility, determine gel transfer characteristics, determine the solubility rate of gaseous helium in the gel, and investigate the gross gel/PPO foam interfacial phenomena. An inside-tank process for scaled-up production of gelled liquid hydrogen was selected. No detectable gel structure degradation occurred during repeated shearing. The viscosity of gelled liquid hydrogen at shear rates of 300/sec and higher is 2 to 5-fold greater than that of neat liquid hydrogen. No clogging problems were encountered during the transfer of gelled liquid hydrogen through warmed transfer lines. The solubility rate of helium in liquid hydrogen was significantly reduced by the presence of gel structure. The boil-off rates from gelled liquid hydrogen were reduced from 25 to 50 percent compared to those observed for the neat liquid hydrogen under compatible conditions. The polyphenylene oxide (PPO) foam insulation was found to be compatible with liquid ethane.

Source record↗
NASA NTRS1973

Improved fireman's compressed air breathing system pressure vessel development program

Prototype high pressure glass filament-wound, aluminum-lined pressurant vessels suitable for use in a fireman's compressed air breathing system were designed, fabricated, and acceptance tested in order to demonstrate the feasibility of producing such high performance, lightweight units. The 4000 psi tanks have a 60 standard cubic foot (SCF) air capacity, and have a 6.5 inch diamter, 19 inch length, 415 inch volume, weigh 13 pounds when empty, and contain 33 percent more air than the current 45 SCF (2250 psi) steel units. The current steel 60 SCF (3000 psi) tanks weigh approximately twice as much as the prototype when empty, and are 2 inches, or 10 percent shorter. The prototype units also have non-rusting aluminum interiors, which removes the hazard of corrosion, the need for internal coatings, and the possibility of rust particles clogging the breathing system.

King, H. A.↗
NASA NTRS1980

Recirculating sprayer for fiber-filled paints

Recirculating paint sprayer applies spray of coarse filler in highly volatile solvent. Sprayer was developed for applying insulation material containing epxoy resin, glass fibers, and inert fillers suspended in chlorinated solvents. Sprayer resists abrasive action of fiberglass filler and chemical activity of solvent. Pump and position ensure more uniform pressure at spray gun without backpressure regulator, which tended to clog in old sprayer.

Major, R. K.↗
NASA NTRS1982

Assembling Multicolor Printing Plates

Improved joining method uses wave-soldering techniques developed for integrated-circuit-board assemblies. Thermosetting plastic is replaced by wave soldering, which applies a thin even coat of solder to mating copper surfaces. This is done after ink holes and channels have been protected by water-soluble, high-temperature solder mask which prevents wetting and clogging.

Waters, W. J.↗
NASA NTRS1982

Nonclogging Liquid-Sodium Nozzles

Reacting liquid sodium with gaseous silicon tetrafluoride effective way of producing high-purity silicon for solar cells; but liquid sodium is such active substance, it readily clogs nozzle through which it is introduced into reactor. Flowing through constriction around sodium-delivery nozzle, silicon tetrafluoride gas cools liquid sodium emerging from nozzle. Sodium-delivery nozzle consists of stainless-steel tube with one-fourth inch outside diameter.

Sanjurjo, A.↗
NASA NTRS1983

Sodium Spray Would Speed Silicon Production

Production rate of solar-grade silicon in sodium/silicon tetrafluoride reactor increase by spray feed. Liquid-sodium droplet size is controlled by pressure of argon gas and by nozzle design. Baffle helps to prevent reactor opening from becoming clogged by reaction products.

Sancier, K. M.↗
NASA NTRS1981

Design and performance of resonant-cavity parallel baffles for duct silencing

Resonant-cavity parallel baffles, either empty or with a thin absorbent lining, have been investigated as an alternative to fiberglass-filled baffles commonly used to control noise emission from large ducts. A method for predicting silencer attenuation is described, and it is shown that the new type of baffle is characterized by an acoustic performance similar to that of fibrous baffles, while being virtually immune to such problems as clogging, erosion, or settling. The emphasis of the study is on insertion loss measurements in a 7 by 10 ft wind tunnel.

Soderman, P. T.↗
NASA NTRS1985

Sealing Mechanical Cryogenic Coolers

Metal bellows used to seal Vuilleumier and Stirling-cycle cryogenic coolers, replacing sliding seals that failed after only 3,000 hours of service. Metal bellows, incorporated in displacer design provide nonrubbing dynamic seal. Lifetime of cryogenic cooler no longer limited by loss of sealing material and by deterioration of regenerators due to clogging by seal debris.

Richter, R.↗