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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 1,261 records · Page 70
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Computational modeling of residual stress formation during the electron beam melting process for Inconel 718

Here, a computational modeling approach to simulate residual stress formation during the electron beam melting (EBM) process within the additive manufacturing (AM) technologies for Inconel 718 is presented in this paper. The EBM process has demonstrated a high potential to fabricate components with complex geometries, but the resulting components are influenced by the thermal cycles observed during the manufacturing process. When processing nickel based superalloys, very high temperatures (approx. 1000 °C) are observed in the powder bed, base plate, and build. These high temperatures, when combined with substrate adherence, can result in warping of the base plate and affect the final component by causing defects. It is important to have an understanding of the thermo-mechanical response of the entire system, that is, its mechanical behavior towards thermal loading occurring during the EBM process prior to manufacturing a component. Therefore, computational models to predict the response of the system during the EBM process will aid in eliminating the undesired process conditions, a priori, in order to fabricate the optimum component. Such a comprehensive computational modeling approach is demonstrated to analyze warping of the base plate, stress and plastic strain accumulation within the material, and thermal cycles in the system during different stages of the EBM process.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Inorganic Ba-Sn Nanocomposite Materials for Sulfate Sequestration from Complex Aqueous Solutions

Selective sequestration of sulfate (SO42-) in the form of barite (BaSO4) from alkaline solutions of high ionic strength containing carbonate at high concentrations resembling legacy radioactive waste generated during plutonium cold war era production is problematic due to the preferential formation of BaCO3. Incorporation of sulfate into the insoluble and thermally stable BaSO4 phase can potentially benefit radioactive waste processing in reducing operational challenges and suppressing volatilization of other waste components such as technetium-99. To enhance selectivity of SO42- sequestration, a series of Ba(II)-Sn(IV) materials was prepared using simple hydrothermal synthesis from different Sn(II) and Sn(IV) precursors. Structural characterization indicated that all obtained products predominantly contained BaSn(OH)6 and Ba2SnO2(OH)4(H2O)10 crystalline phases which were disrupted upon exposure to SO42- due to formation of BaSO4. Performance of the Ba(II)-Sn(IV) materials was tested using complex alkaline solutions simulating radioactive waste containing 0.094 M SO42- and 0.5 M CO32- among other constituents. About 54 – 66% of SO42- was converted to BaSO4 when a quantity of Ba(II)-Sn(IV) material containing approximately a stoichiometric amount of Ba2+ relative to SO42- was used. In comparison, previous studies indicate negligible BaSO4 formation under similar conditions when a simple Ba2+ salt is used. This improvement is attributed to the selective replacement of the Ba(II) stannate by SO42-. Thermal stability of the sulfate-loaded product material up to 1100 °C was demonstrated. Obtained materials offer a convenient and economical option for the selective sequestration or removal of SO42- from carbonate containing solutions.

Johnson, Isaac↗
DOE OSTI2015

An ultra-compact, high-throughput molecular beam epitaxy growth system

We present a miniaturized molecular beam epitaxy (miniMBE) system with an outer diameter of 206 mm, optimized for flexible and high-throughput operation. The three-chamber system, used here for oxide growth, consists of a sample loading chamber, a storage chamber, and a growth chamber. The growth chamber is equipped with eight identical effusion cell ports with linear shutters, one larger port for either a multi-pocket electron beam evaporator or an oxygen plasma source, an integrated cryoshroud, retractable beam-flux monitor or quartz-crystal microbalance, reflection high energy electron diffraction, substrate manipulator, main shutter, and quadrupole mass spectrometer. The system can be combined with ultrahigh vacuum (UHV) end stations on synchrotron and neutron beamlines, or equivalently with other complex surface analysis systems, including low-temperature scanning probe microscopy systems. Substrate handling is compatible with most UHV surface characterization systems, as the miniMBE can accommodate standard surface science sample holders. We introduce the design of the system, and its specific capabilities and operational parameters, and we demonstrate the epitaxial thin film growth of magnetoelectric Cr{sub 2}O{sub 3} on c-plane sapphire and ferrimagnetic Fe{sub 3}O{sub 4} on MgO (001)

36 MATERIALS SCIENCE↗
DOE OSTI2023

PIPII cryoplant non thermal cycling updates

The Proton Improvement Plan-II (PIP-II) is a crucial upgrade to the Fermilab accelerator complex, featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (LINAC) with 23 cryomodules operating at 2K. The LINAC thermohydraulic conditions are satisfied by the cryogenic subsystems: Cryogenic Distribution System (CDS), a helium refrigerator cold box (CB), a warm compression station (WCS) and a helium recovery system (RSYS). The accelerator has a strict requirement of non-thermal cycling of the LINAC cryomodules during planned and unplanned subsystem outages. This paper presents an integrated operating modes analysis of the of the LINAC/CDS thermohydraulic loads satisfied by the CB/WCS cooling system supported by the RSYS inventory management system. The study is based on latest cryoplant and CDS engineering deliverables, as well as the recent performance data from single cryomodule qualification tests performed at the Fermilab PIP-II Injector Test test s tand. The study evaluates both normal and abnormal operating modes, with a focus on identifying integrated scenarios that put subsystems components under stress. The conclusions of this study will help build redundancy to reduce the risk of thermal cycles during planned and unplanned subsystem outages.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2018

Temporal Decompostion of a Distribution System Quasi-Static Time-Series Simulation

This paper documents the first phase of an investigation into reducing runtimes of complex OpenDSS models through parallelization. As the method seems promising, future work will quantify - and further mitigate - errors arising from this process. In this initial report, we demonstrate how, through the use of temporal decomposition, the run times of a complex distribution-system-level quasi-static time series simulation can be reduced roughly proportional to the level of parallelization. Using this method, the monolithic model runtime of 51 hours was reduced to a minimum of about 90 minutes. As expected, this comes at the expense of control- and voltage-errors at the time-slice boundaries. All evaluations were performed using a real distribution circuit model with the addition of 50 PV systems - representing a mock complex PV impact study. We are able to reduce induced transition errors through the addition of controls initialization, though small errors persist. The time savings with parallelization are so significant that we feel additional investigation to reduce control errors is warranted.

14 SOLAR ENERGY↗
DOE OSTI2015

Design study of a laser-cooled infrared sensor

The performance of a solid-state optical refrigerator is the result of a complex interplay of numerous optical and thermal parameters. We present a first preliminary study of an optical cryocooler using ray-tracing techniques. A numerical optimization identified a non-resonant cavity with astigmatism. This geometry offered more efficient pump absorption by the YLF:10%Yb laser-cooling crystal compared to non-resonant cavities without astigmatism that have been pursued experimentally so far. Ray tracing simulations indicate that ~80% of the incident pump light can absorbed for temperatures down to ~100 K. Calculations of heat loads, cooling power, and net payload heat lift are presented. They show that it is possible to cool a payload to a range of 90–100 K while producing a net payload heat lift of 80 mW and 300 mW when pumping a YLF:10%Yb crystal with 20 W and 50 W at 1020 nm, respectively. This performance is suited to cool HgCdTe infrared detectors that are used for sensing in the 8–12 μm atmospheric window. While the detector noise would be ~6× greater at 100 K than at 77 K, the laser refrigerator would introduce no vibrations and thus eliminate sources of microphonic noise that are limiting the performance of current systems.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

BULKI-Store v0.3.2

BULKI-Store is a distributed object storage system optimized for high-performance computing environments. Built with a Rust core and Python bindings, it efficiently manages scientific and machine learning datasets across HPC clusters. The system employs a client-server architecture with MPI integration, enabling seamless scaling on supercomputers like Perlmutter. BULKI-Store's object-oriented approach provides intuitive data organization with rich metadata support, contrasting with traditional file-based solutions. Key optimizations include selective checkpoint loading, unified checkpoint files, and object chunking for large data transfers. For machine learning workloads, BULKI-Store offers advantages through fine-grained access patterns, dynamic data sharing between training instances, and reduced memory pressure. Memory management features include strategic Python GC calls, minimized data copies, and batch processing capabilities. The system leverages Rayon's thread pool for asynchronous data prefetching and supports multiple CPU architectures (ARM64, x86, AMD, RISC-V). By combining performance optimizations with developer-friendly APIs, BULKI-Store addresses the complex data management challenges of modern HPC applications while maintaining compatibility across heterogeneous computing environments.

Zhang, Wei [Lawrence Berkeley National Laboratory ↗
DOE OSTI2024

Managing Increased Electric Vehicle Shares on Decarbonized Bulk Power Systems

Transportation electrification and power sector decarbonization - the convergence of these two trends present a complex planning problem requiring realistic, region-specific modeling and analysis to ensure that both can happen rapidly and cost effectively. This project, funded through the U.S. Department of Energy's Vehicle Technologies Office, models the evolution of the U.S. bulk power system (through 2050) in response to large-scale EV charging across all on-road vehicle segments. We will assess the opportunity and value of demand-side flexibility (i.e., "smart" charging) for reducing energy costs, increasing renewable generation shares, and managing future EV loads on the bulk power system. Overall, this study aims to provide an improved understanding of least-cost solutions for managing EV load growth on the grid and will make high-resolution EV load data sets publicly available for further analysis.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2021

Dehydrogenation of 1-Phenylethanol Catalyzed by Nickel(II)diphosphine Complexes

Catalytic efficacy of the nickel(II)-diphosphine systems in the dehydrogenation of 1-phenylethanol to acetophenone under acceptorless conditions was investigated. Steric and electronic factors of the phosphine ligands were found to play an important role in the catalysis, while the nature of the base used and the reaction conditions, viz. time, temperature, and stoichiometry, have also shown major influence. Based on the preliminary analysis, a homogeneous pathway, perhaps involving nickel hydride species, was proposed. Due to the gradual disintegration of the catalytic species, deterioration of catalytic activity was observed resulting into low to moderate conversions. Among the series of catalysts examined, the highest conversion of 52% was exhibited by the catalyst C4, dichloro(1,2-bis(diphenylphosphino)ethane)nickel(II) (5 mol%), when loaded with 50 mol% of sodium ethoxide in toluene at 120 °C.

1,2 bis(alkyl/arylphosphino) alkane. homogeneous c↗
DOE OSTI2025

Understanding the deformation behavior of the γ rich transformative Fe 38.5 Mn 20 Co 20 Cr 15 Si 5 Cu 1.5 complex concentrated alloy using in situ synchrotron diffraction

In situ tensile testing coupled with synchrotron x-ray diffraction was used to study the deformation behavior of metastability-engineered Fe 38.5 Mn 20 Co 20 Cr 15 Si 5 Cu 1.5 complex concentrated alloy. Monitoring the evolution of phase fraction and strain hardening response allowed the determination of true critical stress for the onset of the transformation-induced plasticity (TRIP) to be ∼375 MPa, preceded by slip starting at ∼255 MPa. In situ EBSD was used to validate the critical stress for transformation at the microstructure level and observe slip traces to confirm prior slip activity before the transformation. Further, a modeling framework based on stacking fault energy (SFE) was developed to predict the critical stress for transformation. Modeling suggested the SFE of the alloy to fall nearly 15 mJ/m 2 , which agrees well with SFE values calculated using synchrotron peak shifting (12 mJ/m 2 ) and thermodynamic calculation (11 mJ/m 2 ). As a result of γ-fcc to ε-hcp phase transformation, new {0002} ε planes emerged parallel to unaligned {111} γ planes with the tensile loading following S-N orientation relationship. Such selective emergence of new diffraction rings corresponding to ε phase is understood based on the reorientation of γ crystals with reference to tensile axis. In conclusion, this approach can be extended to effectively design alloys based on critical stress required for activating different deformation mechanisms to further push the limits of the strength-ductility envelope.

Complex concentrated alloy↗
DOE OSTI2021

High‐efficiency adsorption of various heavy metals by tea residue biochar loaded with nanoscale zero‐valent iron

Abstract Nanoscale zero‐valent iron (nZVI) loaded on tea residue biochar activated with phosphoric acid composites was synthesized. This adsorbent can efficiently adsorb multiple heavy metal ions such as Pb (II), Cr (III), Cu (II), and Ni (II) simultaneously. The adsorption process was found to follow the pseudo‐second‐order kinetic model. Equilibrium adsorption capacities reached 288.18, 162.34, 242.72, and 267.22 mg·g −1 for Pb(II), Cr(III), Cu(II), and Ni(II), respectively. The common interfering ions exhibited lower influence on its adsorption capacity. The adsorption mechanism includes reduction, ion exchange, surface complexation and precipitation. Furthermore, the waste adsorbent was converted into a catalyst in situ, which could catalyze the degradation of Congo red by establishing an electron transfer pathway. This research provides a new concept for the sustainable utilization of industrial tea residues and the harmless treatment of waste nZVI composite adsorbents.

Liu, Shuang↗
DOE OSTI2025

Resin chemistry and particle size influence on stereolithography with silicon carbide

Stereolithography (SLA) is an established process able to produce high resolution polymer parts with complex geometries. Silicon carbide (SiC) has uses in a variety of applications, but traditionally was difficult to manufacture into complex geometries. There have been advances in producing SiC through SLA using a SiC-derived ceramic such as silicon oxycarbide (SiOC). In this study, a slurry using a commercially available resin as the base material with additional modifiers was investigated to create a SiC slurry ready for pressureless sintering. The effects of photoinitiator, dispersant and a bimodal distribution of SiC particle sizes was studied using a design of experiments (DOE). A slurry with a bimodal distribution of 70 % coarse and 30 % fine SiC powder at 40 % solids loading by volume was prepared and successfully printed. Rheology measurements show the slurry to have viscoelastic shear thinning behavior below the recommended 1000 Pas necessary for printing. Printing parameters for the new material on a commercially available SLA printer were studied parametrically. The laser marking speeds found to print the slurry was 260 mm/s and 130 mm/s. A slurry and printing parameters were determined to produce a green part with a proposed debinding cycle.

Herd, Tien [ORNL]↗
DOE OSTI2025

Understanding the structural mechanics of ligated DNA crystals via molecular dynamics simulation

DNA self-assembly is a highly programmable method to construct arbitrary architectures based on sequence complementarity. Among various constructs, DNA crystals are macroscopic crystalline materials formed by assembling motifs via sticky end association. Due to their high structural integrity and size ranging from tens to hundreds of micrometers, DNA crystals offer unique opportunities to study the structural properties and deformation behaviors of DNA assemblies. For example, enzymatic ligation of sticky ends can selectively seal nicks resulting in more robust structures with enhanced mechanical properties. However, the research efforts have been mostly on experiments involving different motif designs, structural optimization, or new synthesis methods, while their mechanics are not yet fully understood. The complex properties of DNA crystals are difficult to study via experiments alone, and numerical simulation can complement and aid the experiments. The coarse-grained molecular dynamics (MD) simulation is a powerful tool that can probe the mechanics of DNA assemblies. Here, we investigate DNA crystals made of four different motif lengths with various ligation patterns (full ligation, major directions, connectors, and in-plane) using oxDNA, an open-source, coarse-grained MD platform. We found that several distinct deformation stages emerge in response to mechanical loading and that the number and the location of ligated nucleotides can significantly modulate structural behaviors. These findings should be useful for predicting crystal properties and thus improving the design.

DNA crystal↗
DOE OSTI2017

1:50 Scale Testing of Three Floating Wind Turbines at MARIN and Numerical Model Validation Against Test Data

The primary goal of the basin model test program discussed herein is to properly scale and accurately capture physical data of the rigid body motions, accelerations and loads for different floating wind turbine platform technologies. The intended use for this data is for performing comparisons with predictions from various aero-hydro-servo-elastic floating wind turbine simulators for calibration and validation. Of particular interest is validating the floating offshore wind turbine simulation capabilities of NREL’s FAST open-source simulation tool. Once the validation process is complete, coupled simulators such as FAST can be used with a much greater degree of confidence in design processes for commercial development of floating offshore wind turbines. The test program subsequently described in this report was performed at MARIN (Maritime Research Institute Netherlands) in Wageningen, the Netherlands. The models considered consisted of the horizontal axis, NREL 5 MW Reference Wind Turbine (Jonkman et al., 2009) with a flexible tower affixed atop three distinct platforms: a tension leg platform (TLP), a spar-buoy modeled after the OC3 Hywind (Jonkman, 2010) and a semi-submersible. The three generic platform designs were intended to cover the spectrum of currently investigated concepts, each based on proven floating offshore structure technology. The models were tested under Froude scale wind and wave loads. The high-quality wind environments, unique to these tests, were realized in the offshore basin via a novel wind machine which exhibits negligible swirl and low turbulence intensity in the flow field. Recorded data from the floating wind turbine models included rotor torque and position, tower top and base forces and moments, mooring line tensions, six-axis platform motions and accelerations at key locations on the nacelle, tower, and platform. A large number of tests were performed ranging from simple free-decay tests to complex operating conditions with irregular sea states and dynamic winds.

17 WIND ENERGY↗
DOE OSTI2022

Off-Gas Design and Testing from Advanced Chlorination Process

Chlorination of Zr alloy cladding with sulfur-chloride reagents is being considered as a means of separating the main metal from alloying elements, imbedded U, actinides, and fission and activation products to purify the Zr. This would allow the Zr to be disposed of as low-level nuclear waste or possibly be recycled. A multistage process was developed that involves several steps and waste streams. Recycling of sulfur-chloride reagents S 2 Cl 2 and SOCl 2 is planned to minimize the waste stream. The generation of off-gas and entrainment of volatiles is anticipated to be minimized. However, given the complex nature of spent nuclear fuel (SNF), some volatile components will be generated, including the solvents themselves; Cl 2 used for the regeneration of S 2 Cl 2 ; volatile fission product chlorides, such as Sb and 3 H; and chlorinated alloying components, such as Sn, Nb, Fe, and Mo. This report discusses the chemical phenomena that might give rise to volatile species and their planned capture. The volatility of the transition metals will depend on their oxidation state and the compounds that are formed, such as Zr tritide. Loading radionuclides in the process off-gas will depend on the inputs to the process. For instance, processing separated Zr to reduce waste will have a much lower loading of radionuclides than if alternative chlorination were used for decladding SNF. Much of the volatile process streams will be part of the solvent recycling, which may involve online scrubbing. Generally, a caustic scrubber should be included in the off-gas to remove acidic vapors (e.g., Cl 2 , SOCl 2 ). The decontamination procedures for removing these species could involve pretreatment (i.e., heating) options or reduction by contact with H 2 . This report discusses these options along with a framework for testing these alternatives in future experiments. Technologies for off-gas capture will leverage those developed in the Materials Recovery and Waste Forms program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Complik: A versatile tool for automatizing the representation of material data in MCNP models - 14412

At the Paul Scherrer Institut, the CASMO/SIMULATE code system is used as reference scheme for core analyses of the Swiss reactors. Besides, Monte Carlo (MC) based neutron transport codes are in parallel being established both for out-of-core applications and full core analyses, in order to provide higher fidelity solutions to problems beyond the modelling capabilities of the standard core modelling methods. In this perspective, a necessity is to be able to conduct the MC calculations at any operating conditions, requiring thus proper initialisation of the thermal-hydraulic feedback as well as at any burnup, prompting the need for a detailed modelling of all material zones in the irradiated fuel assemblies. To tackle the later challenge, the development of the COMPLINK tool, aimed at initialising large-scale MC models of burned core configurations, using as basis upstream 2-D assembly/ 3-D core analyses results, was initiated and is presented in this paper. A main feature is the capability to extend in an automatic manner, a user given MC model in order to represent material data with a higher resolution, keeping track of the location of such materials also within nested repeated structures. This capability prevents the user from the burden of developing specific computational framework for a target application. Since the same functionalities are required to analyse out-of-core spent fuel managements systems, a first verification of COMPLINK is illustrated on the basis of a criticality safety evaluation (CSE) with MCNP6.1 of a Swiss PWR wet storage pool loaded with fresh and burned fuel assemblies. Starting from CASMO-5 depletion calculations at each axial layer of the depleted fuel assemblies and reconstructed based on realistic irradiation histories, COMPLINK is then applied to load the isotopic compositions into the material zones of the corresponding MCNP6.1 assembly models. On this basis, the CSE analyses are conducted with focus on investigating axial and radial modelling effects. All in all, the obtained results are found to be well in line with the impact on CSE expected at the considered burnup levels, providing thus confidence in the correct implementation of the COMPLINK functionalities and confirming its effectiveness as well as efficiency for the initialization of all material zones in large-scale MC models of complex and strongly heterogeneous burned configurations. (authors)

42 ENGINEERING↗
DOE OSTI2026

Cross-slip and easy-glide CRSS in titanium: Theoretical predictions and in-situ TEM measurements

This study investigates the mechanics of prismatic and first-order pyramidal $\langle$a$\rangle$ slip in titanium (Ti), elucidating the physics of easy-glide and cross-slip through a combination of theory and experiments. Screw-character prismatic (Pr) dislocations in Ti are of particular interest because their complex cores can be stable or unstable, leading to activation by either cross-slip or planar glide. To investigate these mechanisms, site-specific micro tensile samples were prepared using focused ion beam (FIB) milling and mounted on a push-to-pull (PTP) device for in-situ transmission electron microscopy (TEM) tensile testing. The in-situ experiments provide direct observations of the onset of dislocation motion and the precise determination of the critical resolved shear stress (CRSS) for the activated mechanisms, and its evolution with load cycling. A comprehensive theory has been developed to predict the CRSS values for easy glide, cross-slip, and multiplication of dislocations. Predicted critical stresses for pyramidal (π)-to-Pr and reverse cross-slip agree closely with the experimental measurements. The latter cross-slip stress is a factor of two higher than that of unobstructed planar slip. The model accounts for overlapping dislocation cores and employs a Wigner-Seitz based cell to evaluate misfit energies. By combining ab initio density functional theory (DFT) with anisotropic elasticity, the framework identifies minimum energy pathways for dislocation glide, which can be intermittent and zig-zag. A simplified expression utilizing (π) and Pr Schmid factor ratios is proposed for critical stress corresponding to (π)-to-Pr cross-slip transition. The results are strongly dependent on crystal orientation, underscoring non-Schmid behavior. Overall, this study explores key critical stress parameters essential for informing higher-scale simulations of plasticity in Ti.

Critical stress↗