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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 OSTI2024

Design of Novel Hot Gas Path Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This report covers the activities associated with the development and evaluation of two high-γ’ superalloys that were designed by external partners on this project, namely Carpenter Technologies Corporation and the University of California-Santa Barbra. One alloy was GammaPrint-700, a cobalt-base superalloy, and the other a nickel-base (Ni-base) superalloy GammaPrint-1100. Both were found to be printable through laser powder bed fusion (LPBF) additive manufacturing, with optimal process parameter sets being identified for each alloy. Further, high temperature mechanical testing was conducted on each alloy that showed both materials performed better than the comparative baseline (LPBF Hastelloy X), with the Ni-base superalloy being down-selected for scaling and printing of the tip shoe components.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Levels of Digitization, Digitalization, and Automation for Advanced Reactors

Much has been written about levels of automation (LOA), but comparatively little has been written about levels of digitization (LODi) and levels of digitalization (LODa). Digitization is a digital representation of analog information and is typical of migration from analog to digital control systems, digitalization involves enhancing the functionality of digital information, and automation changes control from humans to machines. Each of these technology implementations has its own scales, and each forms a viable type of functionality that should be considered not as a continuum toward automation but rather as separate categories of solutions that meet the needs of advanced reactors. In this paper we develop separate LODi, LODa, and LOA scales and demonstrate how conflation of these technologies, using the example of computer-based procedures, can lead to confusion in the design process. With the race to develop advanced reactors, the surest metric of success and safety is proper consideration of the right technology requirements for different control systems.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Optimal Design and Techno-Economic Analysis of 3D-Printed, Intensified Packings for Absorbers and Strippers in Solvent-Based CO 2 Capture

A potential technology for the CO 2 absorption process is utilizing intensified structured packing with embedded cooling/heating channels for continuous heat exchange, which can overcome limitations of discrete methods, such as discrete intercooling and centralized reboilers, to aid in reducing energy consumption and decreasing costs. This work investigates the modeling of intensified packing (IP) for the stripper tower, extending on previous work for the absorber, which distributes heat internally within the column, improving the thermodynamics for the solvent regeneration process. The model includes submodels for steam turbine extraction to produce steam at various qualities as well as a surrogate model for calculating steam enthalpy. A cost model for a plant-scale absorption capture process was developed, allowing for the design of the plant to be optimized, subject to minimizing capture cost using two different power plant flue gas sources. In this optimization, the placement of IP in both towers is optimized to balance the trade-off between enhanced heat transfer and reduced mass transfer volume. For natural gas combined cycle flue gas, the standard process configuration had a minimum cost of $\$$65.40/tonne CO 2 , and considering IP, the minimum capture cost is reduced to $\$$62.73/tonne, with utilization in the stripper column, which reduces yearly costs by up to $\$$2.67 MM/yr. Cooling the absorber through IP, or intercoolers, was only found to be beneficial at higher capture rates, with IP in both towers having a cost of capture of $\$$68.08/tonne at 99.9% capture, a reduction of $\$$12.64/tonne when using only intercoolers at the same capture rate. When capturing from pulverized-coal power plants, the minimum cost of capture when using IP in both towers is $\$$44.18/tonne (at 97% capture), while the standard configuration with and without intercoolers was $\$$45.69 and $\$$47.22 per tonne, respectively. This results in a reduction in yearly costs of $\$$16.98 MM/yr from the base-case configuration. At this higher CO 2 concentration, cooling in the absorber from the IP becomes extremely beneficial, reducing energy consumption by up to 6%.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Design Considerations for the Field Use of International Nuclear Safeguards Technology

The process of developing and deploying safeguards technology should be carried out in such a way that it supports the International Atomic Energy Agency’s (IAEA’s) international safeguards verification mission, while also being efficient in terms of both cost and time. This process, however, may be hindered by a general lack of nuclear facility operating experience among the scientists or engineers designing safeguards technology, or the inability to interact with the IAEA inspector end user. As a result, equipment designers may have difficulty understanding inspector needs and the limitations of using safeguards technology in the field, often leading to inefficiencies (in the form of increased cost and time spent) in the safeguards technology design process. Here, to mitigate this knowledge gap, the Y-12 National Security Complex in Oak Ridge, Tennessee, has developed design considerations that should be incorporated into safeguards technologies, focusing on non-destructive assay equipment. Timelines for integration of these considerations into the design process are also discussed.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

Development of k{sub eff} in the unfolding process of the LOTUS reactor design

An innovative small thermal reactor concept named LOTUS, which is a pool-type reactor aimed at heat supply. The passive concept applied in the LOTUS and it has a separable core. It means that its core can passively unfold into four parts along its central axis only with the buoyancy and gravity when some accidents happen, especially the wall rupture of the pool caused by earthquake, aircraft impact and so on. This idea can effectively enhance the ability of pool-type reactor for resisting some severe accidents. We have executed some pre-computations in order to check a non-supercritical system for the transient simulation. In this paper, the development of k{sub eff} have been calculated by both stepwise steady-state and transient modes using Serpent, as well as including some sensitivity analyses about the k{sub eff} to unfolding velocity, inserting velocity of control rod (CR) and time step. The result showed that k{sub eff} value decreased definitely as the reactor unfolded and the consistent change exposed between the stepwise steady state and transient result when the unfolding angle varied from 0 to 1 degree. However, the stepwise steady state k{sub eff} negatively declined after that angle, which demonstrated that for such a dynamic unfolding change the transient mode was more suitable, peculiarly for considering delayed neutrons and neutron moderation. For sensitivity calculation, the k{sub eff} decreased more rapidly as the unfolding velocity and inserting velocity of CR increased, and a smaller time step corresponded to a more stable change. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Liquid helium fluid dynamics studies. Final Technical Report

Future high energy physics accelerators depend on a number of advanced technologies to open the many doors of scientific discovery. Among these advanced technologies, superconducting magnets and superconducting radio frequency (SRF) cavities are the backbone of the accelerator and detector systems. But all these low temperature systems depend critically on successful and reliable operation of their supporting technologies, among which the liquid helium cooling system is of the utmost importance. To improve the quality of these systems both in terms of efficiency and reliability, a robust helium cryogenics research and development (R&D) effort is required. The proposed research to be conducted by the FSU cryogenics group aims to produce fundamental knowledge that meets this R&D need. The projects that we have completed over the past grant period at Florida State University consist of experimental research on liquid helium fluid dynamics and heat transfer problems relevant to the development of future superconducting particle physics accelerators. Liquid helium is the coolant used in all such facilities and in many of these facilities He II (the low temperature phase of liquid helium also known as superfluid helium) is preferred due to its outstanding heat transfer characteristics. The work consists of two main experimental studies that probe both fundamental as well as practical aspects of liquid helium cooling. The first is a broad and fundamental study of the heat and mass transfer processes that can occur during a sudden catastrophic loss of vacuum (SCLV) incident in a superconducting accelerator. SCLV refers to the remote but extremely critical accident scenario where atmospheric pressure air is allowed to flood into the insulating vacuum system and impinge on the liquid helium cooled surfaces in the accelerator. Safe performance and recovery from such accidents is essential to the reliable operation of superconducting accelerators. The dynamics of this process is quite complex and so our approach is to conduct a series of well-orchestrated experiments that probe the various physical phenomena that can occur during an SCLV event. The experiments are coupled with analytic and numerical analysis in an effort to develop a general understanding of the process and to assist with future accelerator design and development. The second activity is directed toward fundamental understanding of heat and mass transfer in He II, which is essential to the design of superconducting magnets and radio frequency cavities in accelerators. The work consists of flow visualization of the dynamics of He II using laser assisted techniques. Two complementary techniques are used to study the fundamentals of the turbulent state. The first technique uses neutrally buoyant solid hydrogen particles to probe the flow fields of the superfluid and normal fluid components. The other technique uses laser excited He2* molecules as tracers of the normal fluid motion within the He II. The activities also included an effort to use visualization techniques to locate transient hot spots in radio frequency superconducting cavities. Such work provides valuable information about the heat transfer process in He II and its impact on the performance of superconducting devices. The research effort at Florida State University is not directly in support of a specific high energy physics experiment or facility. Rather, the work is general and coordinated with HEP accelerator laboratories to provide valuable insight that can assist with future accelerator development.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

ExaWorks: Workflows for Exascale

Exascale computers will offer transformative capabilities to combine data-driven and learning-based approaches with traditional simulation applications to accelerate scientific discovery and insight. These software combinations and integrations, however, are difficult to achieve due to challenges of coordination and deployment of heterogeneous software components on diverse and massive platforms. We present the ExaWorks project, which can address many of these challenges: ExaWorks is leading a co-design process to create a workflow Software Development Toolkit (SDK) consisting of a wide range of workflow management tools that can be composed and interoperate through common interfaces. We describe the initial set of tools and interfaces supported by the SDK, efforts to make them easier to apply to complex science challenges, and examples of their application to exemplar cases. Furthermore, we discuss how our project is working with the workflows community, large computing facilities as well as HPC platform vendors to sustainably address the requirements of workflows at the exascale.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

A Bayesian Multi-fidelity Neural Network to Predict Nonlinear Frequency Backbone Curves

The use of structural mechanics models during the design process often leads to the development of models of varying fidelity. Often low-fidelity models are efficient to simulate but lack accuracy, while the high-fidelity counterparts are accurate with less efficiency. Here, this paper presents a multi-fidelity surrogate modeling approach that combines the accuracy of a high-fidelity finite element model with the efficiency of a low-fidelity model to train an even faster surrogate model that parameterizes the design space of interest. The objective of these models is to predict the nonlinear frequency backbone curves of the Tribomechadynamics Research Challenge benchmark structure which exhibits simultaneous nonlinearities from frictional contact and geometric nonlinearity. The surrogate model consists of an ensemble of neural networks that learn the mapping between low and high-fidelity data through nonlinear transformations. Bayesian neural networks are used to assess the surrogate model's uncertainty. Once trained, the multi-fidelity neural network is used to perform sensitivity analysis to assess the influence of the design parameters on the predicted backbone curves. Additionally, Bayesian calibration is performed to update the input parameter distributions to correlate the model parameters to the collection of experimentally measured backbone curves.

42 ENGINEERING↗
DOE OSTI2026

Design and Validation of a Cryogenic Dilatometer

This project focuses on the design and development of a cryogenic dilatometer capable of measuring the thermal expansion of materials at extremely low temperatures. Understanding how materials change dimension with temperature is critical for applications involving cryogenic environments, particularly laminated systems housing superconducting magnets, where small dimensional changes can significantly affect performance and reliability. To address this, a dilatometer system was designed to operate within a liquid nitrogen environment while accurately measuring displacements caused by thermal contraction. The purpose of this device is to determine the coefficient of thermal expansion (CTE) of a material. The design process involved defining functional requirements, developing mechanical and thermal concepts for the measurement apparatus, selecting appropriate materials compatible with cryogenic temperatures, and integrating sensors capable of detecting small dimensional changes. The resulting system aims to provide a practical and repeatable method for evaluating material thermal expansion at cryogenic temperatures, supporting research into composite use in superconducting applications that require accurate characterization of material behavior in low-temperature environments.

Schmitt, Nicholas [Northern Illinois U.]↗
DOE OSTI2026

A mathematical design framework for membrane pre-concentration in energy-efficient recovery of fermentation products

Due to the dilute nature of products manufactured via fermentation and cell-free bioprocessing, dewatering is a common unit operation in downstream processing (DSP) for bioproduct recovery, but it is typically energy intensive. To improve DSP energy efficiency for bio-based small molecules, integrating high-pressure membrane pre-concentration is a promising process option. However, this approach is typically constrained by a tradeoff between concentration factor (CF) and product recovery (PR), namely increasing the CF typically results in greater product loss, and vice versa. Here we developed a model that enables process design guidelines to: (i) identify scenarios in which the additional energy consumption and product loss from membrane pre-concentration are justified for use in DSP, and (ii) determine the optimal CF that minimizes process specific energy consumption. We compared the energy consumption of high-pressure membrane-integrated processes to evaporation-only processes and applied the model to an experimental case study for the separation and purification of butyric acid from Clostridium tyrobutyricum fermentation using an in situ product recovery (ISPR) process. The model estimated that integrating a tangential-flow reverse osmosis (RO) pre-concentration unit could reduce process energy consumption up to 45%. The use of advanced membrane pre-concentration technologies, such as negative rejection membranes and organic solvent reverse osmosis (OSRO), have the potential to further reduce the overall process specific energy consumption up to 96%, projected based on modeling. Overall, membrane pre-concentration, especially when strategically integrated prior to an evaporation step with optimized process conditions, holds significant potential for improving DSP energy efficiency, particularly in applications requiring substantial solvent removal for product recovery from dilute mixtures.

09 BIOMASS FUELS↗
DOE OSTI2021

Sludge Batch 10 Frit Development and Variability Study Matrix Design

The Defense Waste Processing Facility (DWPF) is currently preparing to initiate processing of Sludge Batch 10 (SB10), which is comprised of material from Tanks 11H, 13H, 15H, and 26H, and Alternate Feed Stock-2 (AFS-2). H-Canyon also had a need to discard Sodium Reactor Experiment (SRE) material that was stored in Tanks 16.3 and 16.4. Savannah River Remediation (SRR) added a portion of the SRE material to Sludge Batch 9 (SB9) in Tank 40 and the remainder was added to SB10 that is currently being prepared in Tank 51. In support of sludge batch preparation and qualification efforts, SRR requested that the Savannah River National Laboratory (SRNL) complete the following tasks based on the SB10 projections provided by the SRR System Planning group.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

MLSPICE: Machine Learning based SPICE Modeling Platform for Power Magnetics

Electrical power converters are critical to a wide range of applications ranging from renewable integration to transportation electrification, and can be a key factor determining the size, weight, and efficiency of energy conversion systems. Magnetic components are typically the largest and least efficient components in power electronics. While there have been major strides in the modeling and analysis of power semiconductor devices and circuit simulations, the necessary advances in the design of power magnetics have lagged. In this project, we have transformed the modeling and design of power magnetics with machine learning enabled methods and catalyze simultaneous disruptive improvements for ML-based power electronics design tools. A fully automated open-source machine learning based magnetics modeling platform – the MagNet project - with innovations in full stack have been developed to greatly accelerate the design process and provide new insights to magnetic material and geometry design. The ARPA-E funded MagNet platform contains three major building blocks: 1) a ML-Integrated Data Acquisition System (MIDAS): a highly automated data acquisition testbed which is capable of measuring a large number of magnetic cores with a wide range of electrical circuit excitations; 2) a ML-integrated Core Loss Model (MICLM): a machine-learning trained modeling method for modeling the core loss and saturation effects of magnetic materials for arbitrary excitation waveforms; 3) ML-guided Magnetics SPICE Simulation Tool (PMSPICE): a fully integrated CAD tool which can simulate the magnetics in SPICE. It can help the designers to quickly model the linear and non-linear characteristics of magnetic components and evaluate their behavior in SPICE simulations. The developed MagNet system has fully demonstrated the proposed performance target and has been open sourced to the entire power electronics community to advance the modeling and design of power magnetics from many different angles.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Integrating Emerging Polymer Chemistries for the Advancement of Recyclable, Biodegradable, and Biocompatible Electronics

Abstract Through advances in molecular design, understanding of processing parameters, and development of non‐traditional device fabrication techniques, the field of wearable and implantable skin‐inspired devices is rapidly growing interest in the consumer market. Like previous technological advances, economic growth and efficiency is anticipated, as these devices will enable an augmented level of interaction between humans and the environment. However, the parallel growing electronic waste that is yet to be addressed has already left an adverse impact on the environment and human health. Looking forward, it is imperative to develop both human‐ and environmentally‐friendly electronics, which are contingent on emerging recyclable, biodegradable, and biocompatible polymer technologies. This review provides definitions for recyclable, biodegradable, and biocompatible polymers based on reported literature, an overview of the analytical techniques used to characterize mechanical and chemical property changes, and standard policies for real‐life applications. Then, various strategies in designing the next‐generation of polymers to be recyclable, biodegradable, or biocompatible with enhanced functionalities relative to traditional or commercial polymers are discussed. Finally, electronics that exhibit an element of recyclability, biodegradability, or biocompatibility with new molecular design are highlighted with the anticipation of integrating emerging polymer chemistries into future electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Novel Transformational Membranes and Process for CO 2 Capture from Flue Gas (FE0031731)

The objectives of this project are to develop a cost-effective design and fabrication process for a novel transformational membrane and its membrane modules that capture CO 2 from flue gas. Optimization of the novel transformational membrane, scale-up of the membrane to a prototype size of about 20" wide in continuous roll-to-roll fabrication, and construction and testing of a skid for the integrated membrane process will be performed. For the design of this membrane, we use a cost-effective polymer support and coat a thin top layer of the membrane. The simplicity of this membrane design offers a low cost for the membrane element in commercial spiral-wound (SW) configuration (<$2.00/ft 2 or $21.5/m 2 ). The prototype membrane will be used to fabricate 6 pilot-size membrane modules (each about 20" length, 3 modules each at the commercial-size diameter of 8 inches with 35 m 2 membrane area for Stage 1 and 3 modules each at 5-inch diameter with 12 m 2 membrane area for Stage 2) for testing with simulated flue gas at OSU and with actual flue gas at the National Carbon Capture Center, Wilsonville, AL using the skid to capture the CO 2 (at 60 – 90%) with at least 95% CO 2 purity. The prototype membrane modules will be in commercial SW configuration with a minimal pressure drop (<0.103 bar/meter (1.5 psi/meter)). These objectives have been achieved successfully.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Large Area Projection Sintering Technology Development (CRADA Final Report)

This CRADA was formed through support of the Innovation Crossroads program, which has been an invaluable experience for Ascend Manufacturing and our additive manufacturing technology. Without Innovation Crossroads, the research, capital and operational requirements to develop our company would have been too high and Ascend Manufacturing simply would not exist. Our patented and federally funded technology would have gone to waste. Through this CRADA, Ascend has been able to collaborate with the worlds experts in additive manufacturing to assist in developing our state of the art technology. This project assisted in developing a fully scalable 3D printing process, developed an industrial and pilot system design, assisted in the fabrication of a pilot system, allowing us to print components with materials impossible by any other 3D printing process. This work has allowed us to achieve significant follow-on funding to fully commercialize this highly capable manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Radiation Shielding Analysis of Niowave’s Uranium Target Assembly 2 (UTA-2) Facility for Molybdenum-99 Production

Niowave is seeking to develop a commercial medical isotope production process using a low-enriched uranium accelerator-driven subcritical reactor (ADSR) system to produce molybdenum-99. As part of the US Department of Energy national laboratory support to develop low enriched uranium molybdenum-99 production technologies, Oak Ridge National Laboratory is providing research and development resources to assist Niowave in the design and licensing process of its technology. The goals of this work under the radiation shielding task are to assist Niowave in developing a methodology and framework for efficient radiation shielding simulations of their Uranium Target Assembly 2 facility and to provide preliminary radiation shielding calculations and design recommendations for the facility.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Alternative All-Metal Scroll Pump Design

In tritium process systems, vacuum pumps are typically used to evacuate volumes and piping, as well as transfer gas to other parts of the process. This was done using the combination of an all-metal scroll pump with a metal bellows backing pump. The all-metal scroll pump, manufactured by Normetex, has been unavailable since 2012, and efforts continue to find a suitable replacement. The main obstacle is finding a pump that has no oils or polymer components, which degrade when exposed to tritium and introduce corrosive and/or hazardous impurities into the process. There have been development efforts to design an all-metal scroll pump design alternative to the Normetex style. The first generation was fabricated out of machined stainless steel, but the thermal management and increased weight were not ideal. To mitigate the weight, an aluminum version was designed. The tritium holdup on untreated aluminum surfaces can be greater than stainless steel, so the wetted aluminum surfaces were electroless plated in nickel and then electroplated in gold. The development effort outlined in this report details the design of an improved version of the stainless steel version.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗