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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Building America Case Study: Lancaster County Career and Technology Center Green Home 3, Mt Joy, Pennsylvania

Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction.This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate. Of primary interest is the influence of the ICF walls on developing an effective air sealing strategy and selecting an appropriate heating and cooling equipment type and capacity. The domestic water heating system is analyzed for costs and savings to investigate options for higher efficiency electric water heating. A method to ensure mechanical ventilation air flows is examined. The final solution package includes high-R mass walls, very low infiltration rates, multi-stage heat pump heating, solar thermal domestic hot water system, and energy recovery ventilation. This solution package can be used for homes to exceed 2012 International Energy Conservation Code requirements throughout all climate zones and achieves the DOE Challenge Home certification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Insulated Concrete Form Walls Integrated With Mechanical Systems in a Cold Climate Test House

Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction. This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate. Of primary interest is the influence of the ICF walls on developing an effective air sealing strategy and selecting an appropriate heating and cooling equipment type and capacity. The domestic water heating system is analyzed for costs and savings to investigate options for higher efficiency electric water heating. A method to ensure mechanical ventilation air flows is examined. The final solution package includes high-R mass walls, very low infiltration rates, multi-stage heat pump heating, solar thermal domestic hot water system, and energy recovery ventilation. This solution package can be used for homes to exceed 2012 International Energy Conservation Code requirements throughout all climate zones and achieves the DOE Challenge Home certification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Insulated Concrete Form Walls Integrated With Mechanical Systems in a Cold Climate Test House

Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction. This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Understanding and improving anode performance in an alkaline membrane electrolyzer using statistical design of experiments

The behavior of the oxygen-evolving positive electrode (i.e. anode) in the anion exchange membrane water electrolyzer (AEMEL) is complex and influenced by several factors. Very few studies have been performed to understand oxygen evolution reaction (OER) behavior by optimizing the individual factors that influence performance. Here, this study highlights the effects of catalyst loading, catalyst selection, porous transport layer (PTL) type and conductive additive content. The influence of each factor is elucidated through a design of experiments (DoE) approach with a full statistical analysis. Electrochemical data, alongside Pareto charts, parametric trends and their mutual interactions are discussed. This DoE approach is also helpful in making useful predictions and discovering new combinations to be tested. The end result was a high-performance AEMEL able to operate at a current density of 1.0 A/cm 2 at 1.80 V with IrOx OER and PtNi hydrogen evolution reaction (HER) catalysts using 0.3 M KOH fed to the anode. Even lower operating voltage was observed with PbRuOx catalyst at the anode, 1.64 V @ 1.0 A/cm 2 , though the cell decay rate was higher. Lastly, a IrOx/PtNi cell was stably operated continuously for 30 days (720 h) at 1.0 A/cm 2 . This study can serve as a guide for optimal electrode design with insights into component-performance compromises, which can aid in making design choices and performing techno-economic analyses.

08 HYDROGEN↗
DOE OSTI2025

Low Greenhouse Gas (GHG) Vehicle Technologies Research, Development, Demonstration and Deployment Topic 5 Natural Gas Engine Enabling Technologies

A 10 liter natural gas engine has been developed with significant improvements in efficiency while maintaining ultra low NOx emissions and meeting all other EPA criteria emissions limits. This was accomplished through design and analysis of performance components specifically for operation with natural gas in contrast to current production engines which are a minimally modified diesel engine that retain most diesel design features including a flat deck swirl head. The architecture developed here includes a pent roof cylinder head with tumble charge motion and cooling passages specifically optimized for effective cooling around the spark plug and valve bridges. Also in contrast to current production natural gas engines, EGR was not used, in part to avoid the initial cost and warranty expense associated with EGR systems, but also for performance benefits of faster combustion, reduced risk of misfire and high open cycle efficiency due to the turbocharger’s ability to extract energy from the high temperature exhaust. The exhaust manifold uses high temperature material and thermal mechanical fatigue analysis was completed to ensure the ability to withstand high exhaust temperatures without EGR. Other features include dual overhead cam with late intake valve closing Miller cycle and 14:1 compression ratio steel pistons. Low NOx emissions are achieved with stoichiometric combustion and application of a close coupled plus underfloor three way catalysts. The program target of peak brake thermal efficiency of 42% has been demonstrated along with bsNOx of 0.02 g/hp-hr over HD-FTP and RMCSET emissions cycles.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Light Water Reactor Sustainability Program, U.S. Efforts in Support of Examinations at Fukushima Daiichi-2017 Evaluations

Although the accident signatures from each unit at the Fukushima Daiichi Nuclear Power Station (NPS) [Daiichi] differ, much is not known about the end-state of core materials within these units. Some of this uncertainty can be attributed to a lack of information related to cooling system operation and cooling water injection. There is also uncertainty in our understanding of phenomena affecting: a) in-vessel core damage progression during severe accidents in boiling water reactors (BWRs), and b) accident progression after vessel failure (ex-vessel progression) for BWRs and Pressurized Water Reactors (PWRs). These uncertainties arise due to limited full scale prototypic data. Similar to what occurred after the accident at Three Mile Island Unit 2, these Daiichi units offer the international community a means to reduce such uncertainties by obtaining prototypic data from multiple full-scale BWR severe accidents. Information obtained from Daiichi is required to inform Decontamination and Decommissioning activities, improving the ability of the Tokyo Electric Power Company Holdings, Incorporated (TEPCO Holdings) to characterize potential hazards and to ensure the safety of workers involved with cleanup activities. This document, which has been updated to include FY2017 information, summarizes results from U.S. efforts to use information obtained by TEPCO Holdings to enhance the safety of existing and future nuclear power plant designs. This effort, which was initiated in 2014 by the Reactor Safety Technologies Pathway of the Department of Energy Office of Nuclear Energy Light Water Reactor (LWR) Sustainability Program, consists of a group of U.S. experts in LWR safety and plant operations that have identified examination needs and are evaluating TEPCO Holdings information from Daiichi that address these needs. Each year, annual reports include examples demonstrating that significant safety insights are being obtained in the areas of component performance, fission product release and transport, debris end-state location, and combustible gas generation and transport. In addition to reducing uncertainties related to severe accident modeling progression, these insights are being used to update guidance for severe accident prevention, mitigation, and emergency planning. Furthermore, reduced uncertainties in modeling the events at Daiichi will improve the realism of reactor safety evaluations and inform future D&D activities by improving the capability for characterizing potential hazards to workers involved with cleanup activities. Highlights in this FY2017 report include new insights with respect to the forces required to produce the observed Daiichi Unit 1 (1F1) shield plug endstate, the observed leakage from 1F1 components, and the amount of combustible gas generation required to produce the observed explosions in Daiichi Units 3 and 4 (1F3 and 1F4). This report contains an appendix with a list of examination needs that was updated after U.S. experts reviewed recently obtained information from examinations at Daiichi. Additional details for higher priority, near-term, examination activities are also provided. This report also includes an appendix with a description of an updated website that has been reformatted to better assist U.S. experts by providing information in an archived retrievable location, as well as an appendix summarizing U.S. Forensics activities to host the TMI-2 Knowledge Transfer and Relevance to Fukushima Meeting that was held in Idaho Falls, ID, on October 10-14, 2016.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

The Path to High Q-Factors in Superconducting Accelerating Cavities: Flux Expulsion and Surface Resistance Optimization

Accelerating cavities are devices resonating in the radio-frequency (RF) range used to accelerate charged particles in accelerators. Superconducting accelerating cavities are made out of niobium and operate at the liquid helium temperature. Even if superconducting, these resonating structures have some RF driven surface resistance that causes power dissipation. In order to decrease as much as possible the power losses, the cavity quality factor must be increased by decreasing the surface resistance. In this dissertation, the RF surface resistance is analyzed for a large variety of cavities made with different state-of-the-art surface treatments, with the goal of finding the surface treatment capable to return the highest Q-factor values in a cryomodule-like environment. This study analyzes not only the superconducting properties described by the BCS surface resistance, which is the contribution that takes into account dissipation due to quasi-particle excitations, but also the increasing of the surface resistance due to trapped flux. When cavities are cooled down below their critical temperature inside a cryomodule, there is always some remnant magnetic field that may be trapped increasing the global RF surface resistance. This thesis also analyzes how the fraction of external magnetic field, which is actually trapped in the cavity during the cooldown, can be minimized. This study is performed on an elliptical single-cell horizontally cooled cavity, resembling the geometry of cavities cooled in accelerator cryomodules. The horizontal cooldown study reveals that, as in case of the vertical cooldown, when the cooling is performed fast, large thermal gradients are created along the cavity helping magnetic flux expulsion. However, for this geometry the complete magnetic flux expulsion from the cavity equator is more difficult to achieve. This becomes even more challenging in presence of orthogonal magnetic field, that is easily trapped on top of the cavity equator causing temperature rising. The physics behind the magnetic flux expulsion is also analyzed, showing that during a fast cooldown the magnetic field structures, called vortices, tend to move in the same direction of the thermal gradient, from the Meissner state region to the mixed state region, minimizing the Gibbs free energy. On the other hand, during a slow cool down, not only the vortices movement is limited by the absence of thermal gradients, but, also, at the end of the superconducting transition, the magnetic field concentrates along randomly distributed normal-conducting region from which it cannot be expelled anymore. The systematic study of the surface resistance components performed for the different surface treatments, reveals that the BCS surface resistance and the trapped flux surface resistance have opposite trends as a function of the surface impurity content, defined by the mean free path. At medium field value, the BCS surface resistance is minimized for nitrogen-doped cavities and significantly larger for standard niobium cavities. On the other hand, Nitrogen-doped cavities show larger dissipation due to trapped flux. This is consequence of the bell-shaped trend of the trapped flux sensitivity as a function of the mean free path. Such experimental findings allow also a better understanding of the RF dissipation due to trapped flux. The best compromise between all the surface resistance components, taking into account the possibility of trapping some external magnetic field, is given by light nitrogen-doping treatments. However, the beneficial effects of the nitrogen-doping is completely lost when large amount of magnetic field is trapped during the cooldown, underlying the importance of both cooldown and magnetic field shielding optimization in high quality factors cryomodules.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

CMB-PAInT: An inpainting tool for the cosmic microwave background

Abstract The presence of astrophysical emissions in microwave observations forces us to perform component separation to extract the Cosmic Microwave Background (CMB) signal. However, even in the most optimistic cases, there are still strongly contaminated regions, such as the Galactic plane or those with emission from extragalactic point sources, which require the use of a mask. Since many CMB analyses, especially the ones working in harmonic space, need the whole sky map, it is crucial to develop a reliable inpainting algorithm that replaces the values of the excluded pixels by others statistically compatible with the rest of the sky. This is especially important when working withQandUsky maps in order to obtainE- andB-mode maps which are free fromE-to-Bleakage. In this work we study a method based on Gaussian Constrained Realizations (GCR), that can deal with both intensity and polarization. Several tests have been performed to asses the validation of the method, including the study of the one-dimensional probability distribution function (1-PDF),E- andB-mode map reconstruction, and power spectra estimation. We have considered two scenarios for the input simulation: one case with only CMB signal and a second one including also Planck PR4 semi-realistic noise. Even if we are limited to low resolution maps, N side = 64 ifT,QandUare considered, we believe that this is a useful approach to be applied to future missions such as LiteBIRD, where the target are the largest scales.

Astronomy & Astrophysics↗
DOE OSTI2019

U.S. Efforts in Support of Examinations at Fukushima Daiichi: 2019 Evaluations

Much is still not known about the end-state of core materials in each unit that was operating on March 11, 2011 at the Fukushima Daiichi Nuclear Power Station (Daiichi). Information obtained from Daiichi is required to inform Decontamination and Decommissioning (D&D) activities, improving the ability of the Tokyo Electric Power Company Holdings, Incorporated (TEPCO Holdings) to characterize potential hazards and to ensure the safety of workers involved with cleanup activities. This document, which has been updated to include Fiscal Year 2019 (FY2019) information, summarizes results from a U.S. effort to review Daiichi information and extract insights to enhance the safety of existing and future nuclear power plant designs. This U.S. effort, which was initiated in 2014 by the Department of Energy Office of Nuclear Energy (DOE-NE), is completed by a group of experts in reactor safety and plant operations that identify examination needs and evaluate recent Daiichi examination data to address these needs. Each year, annual reports are issued that document significant safety insights being obtained in areas of special emphasis. For FY2019, the areas emphasized by the expert panel include component performance, radionuclide surveys and sampling, debris end-state location, combustible gas effects, and plant operations and maintenance. In addition to reducing uncertainties related to severe accident modeling progression, these insights have and continue to be used to update guidance for severe accident prevention, mitigation, and emergency planning. Reduced uncertainties in modeling the events at Daiichi improve the realism of reactor safety evaluations that inform future D&D activities. In addition, the process established by this U.S. effort provides an example that Japan may wish to implement in future international efforts to support D&D. As emphasized in this FY2019 report, important insights are being gained from examinations of the affected units at Daiichi. Although many results from prior years have been moved to appendices, key areas of interest are highlighted in the main document. For example, larger intact components and fuel containing materials observed on the floor of the primary containment and retained on ex-vessel structures continue to be emphasized because of insights that may be gained with respect to vessel failure and ex-vessel interactions with structures and concrete. In addition, the main report presents insights gained by focused evaluations of plant data because of potential use of systems and components during severe accident conditions and alternate perspectives regarding accident progression that may be inferred from such data. The report also illustrates how systems analysis codes can be applied to reduce uncertainties about the progression of events at Daiichi and how practical insights obtained from Daiichi can be used to enhance radiation safety for the existing fleet. Recent and planned updates to systems analysis codes are also discussed. As in prior years, this report contains an appendix with a list of examination needs that was updated after U.S. experts reviewed recently obtained information from Daiichi. Additional details for higher priority, near-term, examination activities are also provided. This report also includes an appendix with a description of a website that was developed to assist U.S. experts by providing information in an archived retrievable location.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Hybrid Hydraulic-Electric Architecture (HHEA) for Mobile Machines (Final Report)

Traditionally, off-road mobile machines such as excavators and wheel loaders are primarily powered by hydraulics, and throttling valves are used to control their work circuits. In recent years, two general trends are towards more energy efficient systems and electrification. With electrification, both efficiency and control performance can be improved by the elimination of throttling losses and the use of high-bandwidth inverter control. Electrification is generally accomplished with Electro-hydraulic actuators (EHA) but they are limited to lower powered systems due to the high cost of electric machines capable of high power or high torque. This project proposes a new system architecture for off-road vehicles - Hybrid Hydraulic Electric Architecture (HHEA) to improve efficiency and control performance without requiring large electric machines. The widely applicable architecture combines hydraulic power and electric power in such a way that the majority of power is provided hydraulically while electric drives are used to modulate this power. In particular, HHEA utilizes multiple common pressure rails to transmit the majority of power and small electric machines to modulate the power. The energy-saving potential of the the HHEA has been validated for the work circuits of a variety of mobile machines, from small 5-ton excavators to medium sized 20-ton excavators and wheel loaders, and representative duty cycles to reduce energy input by 50-80% compared to the commercial state-of-art load-sensing systems. In addition, the corner power requirements of the electrical machines can be downsized by 85% compared to the EHA approach. Various tradeoff studies have also been conducted, including sensitivities to individual components performances, controllers, accumulator sizes, and variations of the system architecture etc. A control strategy has been developed to maintain or exceed the motion control precision compared to current systems. The motion control strategy consists of a nominal controller, based on a passivity-based backstepping design, and a transition controller, based on least-norn feedforward design. The nominal controller is used in between common pressure rail switches whereas the transition controller compensates for any disturbance that common pressure rail switchings inflict on the system. The control strategy has been experimentally validated on both a medium pressure (200bar) hardware-in-the-loop (HIL) testbed and a high pressure (300+bar) HIL testbed. An efficient and power-dense integrated electric-hydraulic machine consisting of an axial flux electric machine and a radial hydrostatic piston hydraulic machine has been designed, constructed and tested. The machine has an active material power density of 6.1kW/kg, a rated speed of 12500 RPM, and a design efficiency of 85%. This is among the highest power density electric machines using conventional materials. While the integrated machine was designed for modulating the hydraulic power within the HHEA, it can also be used in other applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Computational Design of Alloys for Energy Technologies

Advanced materials that maintain their mechanical performance under elevated temperatures, corrosive environments, and a range of static and evolving stresses are needed to improve the efficiency and reduce the environmental impact of a wide spectrum of energy technologies. For instance, cost-efficient alloys that can withstand high temperatures (e.g., 700 °C) have a critical role in improving the efficiency and economics of power generation to support decarbonization of the energy sector; such is true of both the nuclear and fossil energy sectors. Considering both the threats of the energy crisis, namely soaring costs of greenhouse gas emission-producing energy and climate change, it is essential to increase the pace of material discovery and enable rapid paths for material qualification to advance clean energy technologies. Conventionally, alloy development has followed a slow Edisonian process that uses repeated cycles of making, characterizing, and modifying to arrive at optimum composition and processing conditions to achieve the desired component performance. This optimization is followed by the necessary stepwise materials qualification. Furthermore, the increasing adoption of sound data management and physics-informed machine learning represents the next step in the acceleration of materials design and development. In the integrated computational materials engineering (ICME) approach, computational modeling and simulation data from different length and time scales can be combined with complex microstructural details from multimodal experimental characterization and selective property testing to close the design loop for rapid alloy development.

Computational Design Of Materials↗
DOE OSTI2013

Miscibility Evaluation Of The Next Generation Solvent With Polymers Currently Used At DWPF, MCU, And Saltstone

The Office of Waste Processing, within the Office of Technology Innovation and Development, funded the development of an enhanced Caustic-Side Solvent Extraction (CSSX) solvent for deployment at the Savannah River Site for removal of cesium from High Level Waste. This effort lead to the development of the Next Generation Solvent (NGS) with Tris (3,7-dimethyl octyl) guanidine (TiDG). The first deployment target for the NGS solvent is within the Modular CSSX Unit (MCU). Deployment of a new chemical within an existing facility requires verification that the new chemical components are compatible with the installed equipment. In the instance of a new organic solvent, the primary focus is on compatibility of the solvent with organic polymers used in the affected facility. This report provides the calculated data from exposing these polymers to the Next Generation Solvent. An assessment of the dimensional stability of polymers known to be used or present in the MCU, Defense Waste Processing Facility (DWPF), and Saltstone facilities that will be exposed to the NGS showed that TiDG could selectively affect the elastomers and some thermoplastics to varying extents, but the typical use of these polymers in a confined geometry will likely prevent the NGS from impacting component performance. The polymers identified as of primary concern include Grafoil ® (flexible graphite), Tefzel ® , Isolast ® , ethylene-propylene-diene monomer (EPDM) rubber, nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), ultra high molecular weight polyethylene (UHMWPE), and fluorocarbon rubber (FKM). Certain polymers like NBR and EPDM were found to interact mildly with NGS but their calculated swelling and the confined geometry will impede interaction with NGS. In addition, it was found that Vellumoid (cellulose fibers-reinforced glycerin and protein) may leach protein and Polyvinyl Chloride (PVC) may leach plasticizer (such as Bis-Ethylhexyl-Phthalates) into the NGS solvent. Either case will not impact decontamination or immobilization operations at Savannah River Site (SRS). Some applications have zero tolerance for dimensional changes such as the operation of valves while other applications a finite dimensional change improves the function of the application such as seals and gaskets. Additional considerations are required before using the conclusions from this work to judge outcomes in field applications. Decane, a component of Isopar L that is most likely to interact with the polymers, mildly interacted with the elastomers and the propylene based polymers but their degree of swelling is at most 10% and the confined geometry that they are typically placed in indicate this is not significant. In addition, it was found that Vellumoid may leach protein into the NGS solvent. Since Vellumoid is used at the mixer in Saltstone where it sees minimum quantities of solvent, this leaching has no effect on the extraction process at MCU or the immobilization process at saltstone. No significant interaction is expected between MaxCalix and the polymers and elastomers used at MCU, DWPF, and Saltstone. Overall, minimal and insignificant interactions are expected on extraction and immobilization operations when MCU switches from CSSX to NGS solvent. It is expected that contacting NGS will not accelerate the aging rate of polymers and elastomers under radiation and heat. This is due to the minimal interaction between NGS and the polymers and the confined geometries for these polymers. SRNL recommends the use of the HSP method (for screening) and some testing to evaluate the impact of other organic such as alcohols, glycolate, and their byproducts on the polymers used throughout the site.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Self-supervised learning of spatiotemporal thermal signatures in additive manufacturing using reduced order physics models and transformers

Microstructure control via additive manufacturing has enormous potential as manufacturers, materials scientists, and designers alike seek to exploit novel fabrication technologies to improve component performance. Recent works have demonstrated the feasibility of producing materials with controlled microstructures across various length scales. However, the experimental approach towards exploring the process-structure space can be laborious and costly. This is particularly true if also considering scan pattern optimization which is well suited for processes such as powder bed fusion electron beam melting. In this work we propose an approach for encoding additive manufacturing layer-wise thermal response signatures using self-supervised representation learning. Thermal simulations from a reduced order model are utilized to estimate the spatiotemporal response during printing. A machine learning framework, using video-transformers, is utilized to efficiently distill spatiotemporal patterns into a compact latent space representation. This latent state representation encodes the relevant physics which is then utilized to establish a data-driven process-structure model for an additively manufactured Ni-based superalloy. In conclusion, the proposed methodology could potentially be used towards in-situ process monitoring, scan pattern experimental design, and component qualification.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Corrosion Behavior of Wire Electrical Discharge Machined Surfaces of P91 Steel

The extensive usage of P91 steel in certain reactor components requires its precision fabrication by wire electrical discharge machining (WEDM). The WEDM cut surfaces consist of primarily re-melted and solidified layer (recast layer) of 2-8 µm. The recast layer is a result of fast removal of heat by unaffected metallic substrate and dielectric medium leading to rapid cooling. The WEDM surface is expected to affect the component performance in terms of its corrosion properties. The microstructural changes taking place due to EDM cutting of P91 steel bring about a drastic change in the electrochemical response of surface as compared to that for bulk P91 steel. The surface microstructure is shown to alter the passivation behavior and resistance to localized corrosion. Electrochemical polarization studies were done to evaluate passivation, pitting and intergranular corrosion (IGC) behavior and field emission gun—scanning electron microscopy was used for microstructural characterization of P91 steel surfaces. The passivation behavior for P91 steel WEDM cut surfaces was better than that for diamond polished surface. But pitting corrosion resistance decreased for the P91 steel WEDM surface which is a result of inhomogeneities in the microstructure of recast layer. The IGC resistance though increased due to the decreased grain size in the surface layer.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Data Center Facility Monitoring with Physics Aware Approach

U.S. Department of Energy's National Renewable Energy Laboratory (NREL) hosts one of the world's most energy-efficient HPC data centers; this system uses component-level warm-water liquid cooling to efficiently remove heat from the data center and capture it for reuse in the building or rejection to the atmosphere. Given the complexity of this system, building data-driven tools for holistically monitoring and operating the entire data center is a priority for ensuring maximal efficiency and resiliency. In this advanced smart facility, over one million metrics are recorded per minute using state-of-the-art streaming data architecture and software to capture and process the state of the system in real time. Here we detail two efforts to effectively analyze, visualize, and interpret this large volume streaming data. We have developed a novel, flexible system for identifying and visualizing individual metric anomalies and component performance across the data center through automatic metadata extraction and physically-motivated visualization for quick interpretation. Additionally, to directly connect system maintenance to data stream processing we explore a physics informed multi-metric drift and anomaly detection application to detect scale-build up in heat exchangers.

anomaly detection↗
DOE OSTI2012

Progress towards an Optimization Methodology for Combustion-Driven Portable Thermoelectric Power Generation Systems

Enormous military and commercial interests exist in developing quiet, lightweight, and compact thermoelectric (TE) power generation systems. This paper investigates design integration and analysis of an advanced TE power generation system implementing JP-8 fueled combustion and thermal recuperation. Design and development of a portable TE power system using a JP-8 combustor as a high temperature heat source and optimal process flows depend on efficient heat generation, transfer, and recovery within the system are explored. Design optimization of the system required considering the combustion system efficiency and TE conversion efficiency simultaneously. The combustor performance and TE sub-system performance were coupled directly through exhaust temperatures, fuel and air mass flow rates, heat exchanger performance, subsequent hot-side temperatures, and cold-side cooling techniques and temperatures. Systematic investigation of this system relied on accurate thermodynamic modeling of complex, high-temperature combustion processes concomitantly with detailed thermoelectric converter thermal/mechanical modeling. To this end, this work reports on design integration of systemlevel process flow simulations using commercial software CHEMCADTM with in-house thermoelectric converter and module optimization, and heat exchanger analyses using COMSOLTM software. High-performance, high-temperature TE materials and segmented TE element designs are incorporated in coupled design analyses to achieve predicted TE subsystem level conversion efficiencies exceeding 10%. These TE advances are integrated with a high performance microtechnology combustion reactor based on recent advances at the Pacific Northwest National Laboratory (PNNL). Predictions from this coupled simulation established a basis for optimal selection of fuel and air flow rates, thermoelectric module design and operating conditions, and microtechnology heat-exchanger design criteria. This paper will discuss this simulation process that leads directly to system efficiency power maps defining potentially available optimal system operating conditions and regimes. This coupled simulation approach enables pathways for integrated use of high-performance combustor components, high performance TE devices, and microtechnologies to produce a compact, lightweight, combustion driven TE power system prototype that operates on common fuels.

Heat Transfer↗
DOE OSTI2021

Integrating helicoid channels for passive control of fiber alignment in direct-write 3D printing

3D printing of fiber-reinforced composites has been receiving increasing attention as an efficient additive approach enabling lightweight, functional, and high-performance components required for industrial applications. The properties of fiber composites significantly depend on internal microstructures, including fiber orientation, distribution, and degree of alignment. Although multiple strategies have been introduced for controlling the fiber composites microstructures, these strategies are mostly active approaches relying on additional control of mechatronics parts, external forces, or intentionally introduced unstable flows inside narrow nozzles. These methods suffer from higher risk of nozzle clogging and requiring extra parts in 3D printing. Here, we introduce helicoid channels into extrusion system as a passive approach to control the fiber alignment without any additional moving parts in direct-write 3D printing. The helicoid channels automatically guide the composite inks and align fibers before flowing into narrow nozzle space, avoiding clogging and improving printability. The analyses indicate that both helicoid surface to volume ratio and helix angle affect the pre-alignment of fibers, leading to tunable mechanical properties of printed fiber-reinforced composites with increased stiffness and strength up to 77.6% and 47.8%, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A scalable digital platform for the use of digital twins in additive manufacturing

We report that while Additive Manufacturing promises to reshape the manufacturing landscape, challenges related to part, and process qualification hinder its widespread adoption. The Instance-Qualified approach seeks to qualify individual parts, even for processes with high variability, by leveraging the concept of a digital twin. This work proposes a scalable cyberphysical infrastructure to enable the construction and use of such digital twins. This work also introduces the concept of an Augmented Intelligence Relay, which allows Artificial Intelligence algorithms to predict component performance for a given application even when it is impractical to perform a large number of physical tests.

36 MATERIALS SCIENCE↗