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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 OSTI2016

The New S-RAM Air Variable Compressor/Expander for Heat Pump and Waste Heat to Power Application

S-RAM Dynamics (S-RAM) has designed an innovative heat pump system targeted for commercial and industrial applications. This new heat pump system is more efficient than anything currently on the market and utilizes air as the refrigerant instead of hydrofluorocarbon (HFC) refrigerants, leading to lower operating costs, minimal environmental costs or concerns, and lower maintenance costs. The heat pumps will be manufactured in the United States. This project was aimed at determining the feasibility of utilizing additive manufacturing to make the heat exchanger device for the new heat pump system. ORNL and S-RAM Dynamics collaborated on determining the prototype performance and subsequently printing of the prototype using additive manufacturing. Complex heat exchanger designs were fabricated using the Arcam electron beam melting (EBM) powder bed technology using Ti-6Al-4V material. An ultrasonic welding system was utilized in order to remove the powder from the small openings of the heat exchanger. The majority of powder in the small chambers was removed, however, the amount of powder remaining in the heat exchanger was a function of geometry. Therefore, only certain geometries of heat exchangers could be fabricated. SRAM Dynamics evaluated a preliminary heat exchanger design. Although the results of the additive manufacturing of the heat exchanger were not optimum, a less complex geometry was demonstrated. A sleeve valve was used as a demonstration piece, as engine designs from S-RAM Dynamics require the engine to have a very high density. Preliminary designs of this geometry were successfully fabricated using the EBM technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Unmanned air vehicle (UAV) ultra-persitence research

Sandia National Laboratories and Northrop Grumman Corporation Integrated Systems, Unmanned Systems (NGIS UMS) collaborated to further ultra-persistence technologies for unmanned air vehicles (UAVs). The greatest shortfalls in UAV capabilities have been repeatedly identified as (1) insufficient flight persistence or 'hang time,' (2) marginal electrical power for running higher power avionics and payload systems, and (3) inadequate communications bandwidth and reach. NGIS UMS requested support from Sandia to develop an ultra-persistent propulsion and power system (UP3S) for potential incorporation into next generation UAV systems. The team members tried to determine which energy storage and power generation concepts could most effectively push UAV propulsion and electrical power capabilities to increase UAV sortie duration from days to months while increasing available electrical power at least two-fold. Primary research and development areas that were pursued included these goals: perform general system engineering and integration analyses; develop initial thermal and electrical power estimates; provide mass, volume, dimensional, and balance estimates; conduct preliminary safety assessments; assess logistics support requirements; perform, preliminary assessments of any security and safeguards; evaluate options for removal, replacement, and disposition of materials; generally advance the potential of the UP3S concept. The effort contrasted and compared eight heat sources technologies, three power conversion, two dual cycle propulsion system configurations, and a single electrical power generation scheme. Overall performance, specific power parameters, technical complexities, security, safety, and other operational features were successfully investigated. Large and medium sized UAV systems were envisioned and operational flight profiles were developed for each concept. Heat source creation and support challenges for domestic and expeditionary operations were considered. Fundamental cost driver analysis was also performed. System development plans were drafted in order to determine where the technological and programmatic critical paths lay. As a result of this effort, UAVs were to be able to provide far more surveillance time and intelligence information per mission while reducing the high cost of support activities. This technology was intended to create unmatched global capabilities to observe and preempt terrorist and weapon of mass destruction (WMD) activities. Various DOE laboratory and contractor personnel and facilities could have been used to perform detailed engineering, fabrication, assembly and test operations including follow-on operational support. Unfortunately, none of the results will be used in the near-term or mid-term future. NGIS UMS and SNL felt that the technical goals for the project were accomplished. NGIS UMS was quite pleased with the results of analysis and design although it was disappointing to all that the political realities would not allow use of the results. Technology and system designs evaluated under this CRADA had previously never been applied to unmanned air vehicles (UAVs). Based upon logistic support cost predictions, because the UAVs would not have had to refuel as often, forward basing support costs could have been reduced due to a decrease in the number and extent of support systems and personnel being required to operate UAVs in remote areas. Basic application of the advanced propulsion and power approach is well understood and industry now understands the technical, safety, and political issues surrounding implementation of these strategies. However, the overall economic impact was not investigated. The results will not be applied/implemented. No near-term benefit to industry or the taxpayer will be encountered as a result of these studies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2014

Investigation of Mixed Oxide Catalysts for NO Oxidation

The oxidation of engine-generated NO to NO2 is an important step in the reduction of NOx in lean engine exhaust because NO2 is required for the performance of the LNT technology [2], and it enhances the activities of ammonia selective catalytic reduction (SCR) catalysts [1]. In particular, for SCR catalysts an NO:NO2 ratio of 1:1 is most effective for NOx reduction, whereas for LNT catalysts, NO must be oxidized to NO2 before adsorption on the storage components. However, NO2 typically constitutes less than 10% of NOx in lean exhaust, so catalytic oxidation of NO is essential. Platinum has been found to be especially active for NO oxidation, and is widely used in DOC and LNT catalysts. However, because of the high cost and poor thermal durability of Pt-based catalysts, there is substantial interest in the development of alternatives. The objective of this project, in collaboration with partner General Motors, is to develop mixed metal oxide catalysts for NO oxidation, enabling lower precious metal usage in emission control systems. [1] M. Koebel, G. Madia, and M. Elsener, Catalysis Today 73, 239 (2002). [2] C. H. Kim, G. S. Qi, K. Dahlberg, and W. Li, Science 327, 1624 (2010).

diesel oxidation catalyst↗
DOE OSTI2018

PIPER: Performance Insights for Programmers and Exascale Runtimes

During the lifetime of the project, the PIPER at the University of Utah worked in collaboration with the team from the partner institutions to establish a set of software tools for analyzing and improving the performance parallel computing tools. These activities complement and complete the work performed by the other X-Stack 2 projects with the definition of a common data models and computing infrastructures, which have been a central element in the targeted performance analysis pipeline and new programming models. The University of Utah team have focused mainly on developing data analysis and visualization systems to facilitate exploration, comparison and evaluation of the behavior and performance of complex algorithms in modern HPC infrastructures. This is involved several demonstrations of the performance achieved and presentation of the results in a way that facilitates the users understand bottlenecks and ways to overcome them. One major focus of the University of Utah activities has been the analysis of the performance characteristics of Fat-Tree and Dragonfly topology networks. The work involved the development of practical visualization systems especially in collaboration with the team at LLNL, and published several papers and gave invited talks at prestigious venues such as the Salishan Conference on High-Speed Computing or the International Conference on High Performance Computing, Data, and Analytics. In addition, the university of Utah team has advanced the core activities on analyzing the performance characteristics of I/O and other data movement systems and their practical use for scaling Uintah and other simulation codes poised for use in the exascale computing environments of the future.

42 ENGINEERING↗
DOE OSTI2018

Developing Novel Multifunctional Materials for High-Efficiency Electrical Energy Storage

This is the final report for the program “Developing Novel Multifunctional Materials for High-efficiency Electrical Energy Storage”, funded by The U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL), and performed by University of Tennessee, from September 01, 2013 to August 31, 2018. Securing a sustainable energy economy by developing affordable and clean energy from renewable energy is a central element to the mission of DOE/NETL. To further this mission, NETL funds research and development of novel multifunctional materials that can be used for high-efficiency electrical energy storage. The main objective of this research program is to conduct fundamental and applied research that lead to successful development and demonstration of novel multifunctional materials, which can improve the efficiency and reduce the cost of hydrogen production with water electrolysis. The specific objectives of this research program include: 1) Design, fabrication and demonstration of thin/well-tunable liquid/gas diffusion layer (TT-LGDLs) with different pore morphologies, including pore sizes and pore porosities. 2) Development of comprehensive computational models of proton exchange membrane water electrolyzer cell (PEMECs) for the investigation of influence of different operating conditions and physical design parameters on its performance. 3) Surface modification of TT-LGDLs for better catalyst access and product/reactant removal, and smaller interfacial contact resistance (ICR). To achieve the above challenging goals, a multidisciplinary research team was formed to work on fundamental and applied research on the following three major technical areas: 1) Design, fabrication and demonstration of thin/well-tunable LGDLs (TT-LGDLs) by using photolithography and wet etching of thin titanium (Ti) foils. During the project period, the team has successfully fabricated TT-LGDLs with different pore morphologies, including pore sizes and pore porosities. The manufacturing steps mainly include cleaning thin Ti foil, supporting the foils, applying photoresist, patterning the photoresist with designed mask, exposing and developing, etching, removing photoresist, and lift-off and cleaning. The manufactured TT-LGDLs were characterized with optical microscopies and scanning electron microscopies. Their pore morphologies, including pore size and porosity, were derived based on advanced image process. The feasibility for scale-up manufacturing has been demonstrated. The TT-LGDLs have been successfully investigated for water splitting in PEMECs, which showing better performance than their counterparts fabricated with the traditional fiber-based materials. 2) Comprehensive computational modeling of a PEMEC. A comprehensive computational model has been successfully developed, and the influence of different operating conditions and physical design parameters on its performance has been investigated, including operating temperature, pressure, exchange current density, electrode thickness, membrane thickness, and interfacial resistance. Results obtained from the present model provide a comprehensive understanding of design parameter effects and consequently improve the design/performance in a PEMEC. 3) Surface modification of TT-LGDLs. The proposed surface modifications of TT-LGDLs by sputter coating and/ electroplating have been successfully demonstrated. It has been found that the performance of PEMECs can be improved by both methods, and the thickness of the electroplated gold thin layer has limited effects on the performance. With the help of the surface modifications, the PEMECs achieved the best ever performance compared with the public literatures. In addition to completion of the proposed method, microporous layers (MPLs) with both irregular micro and sphere nano titanium particles on novel TT-LGDLs was developed for the first time. The MPLs were fabricated by a low-temperature air spraying method, which provide a better catalyst access and product/reactant removal. In summary, under the close collaborations among the research team, all the tasks have been completed and the proposed research objectives have been fulfilled. All the technical milestones have been achieved and the project has been completed successfully. The technical breakthroughs obtained under this project provide novel LGDLs with well-tunable pore morphologies that can significantly improve the performance of water splitting and energy storage. This development can be directly used in existing and next generation energy storage and fuel systems.

08 HYDROGEN↗
DOE OSTI2015

Impact of Different Standard Type A7A Drum Closure-Ring Practices on Gasket Contraction and Bolt Closure Distance– 15621

The Department of Energy, the Savannah River National Laboratory, several manufacturers of specification drums, and the United States Department of Transportation (DOT) are collaborating in the development of a guidance document for DOE contractors and vendors who wish to qualify containers to DOT 7A Type A requirements. Currently, the effort is focused on DOT 7A Type A 208-liter (55-gallons) drums with a standard 12-gauge bolted closure ring. The U.S. requirements, contained in Title 49, Part 178.350 “Specification 7A; general packaging, Type A specifies a competent authority review of the packaging is not required for the transport of (Class 7) radioactive material containing less than Type A quantities of radioactive material. For Type AF drums, a 4 ft. regulatory free drop must be performed, such that the drum “suffers maximum damage.” Although the actual orientation is not defined by the specification, recent studies suggest that maximum damage would result from a shallow angle top impact, where kinetic energy is transferred to the lid, ultimately causing heavy damage to the lid, or even worse, causing the lid to come off. Since each vendor develops closure recommendations/procedures for the drums they manufacture, key parameters applied to drums during closing vary based on vendor. As part of the initial phase of the collaboration, the impact of the closure variants on the ability of the drum to suffer maximum damage is investigated. Specifically, closure testing is performed varying: 1) the amount of torque applied to the closure ring bolt; and, 2) stress relief protocol, including: a) weight of hammer; and, b) orientation that the hammer hits the closure ring. After closure, the amount of drum lid gasket contraction and the distance that the closure bolt moves through the closure ring is measured.

42 ENGINEERING↗
DOE OSTI2025

Measuring the muon content of inclined air showers using AERA and the water-Cherenkov detectors of the Pierre Auger Observatory

We present a novel approach for assessing the muon content of air showers with large zenith angles on a combined analysis of their radio emission and particle footprint. We use the radiation energy reconstructed by the Auger engineering radio array (AERA) as an energy estimator and determine the muon number independently with the water-Cherenkov detector array of the Pierre Auger Observatory, deployed on a 1500 m grid. We focus our analysis on air showers with primary energy above 4 EeV to ensure full detection efficiency. Over approximately ten years of accumulated data, we identify a set of 40 high-quality events that are used in the analysis. The estimated muon contents in data are compatible with those for iron primaries as predicted by current-generation hadronic interaction models. This result can be interpreted as a deficit of muons in simulations as a lighter mass composition has been established from X max measurements. This muon deficit was already observed in previous analyses of the Auger Collaboration and is confirmed using hybrid events that include radio measurements for the first time.

Abdul Halim, A. [Adelaide U.]↗
DOE OSTI2014

NOVA making stuff: Season 2

Over the course of four weeks in fall 2013, 11.7 million Americans tuned in to PBS to follow host David Pogue as he led them in search of engineering and scientific breakthroughs poised to change our world. Levitating trains, quantum computers, robotic bees, and bomb-detecting plants—these were just a few of the cutting-edge innovations brought into the living rooms of families across the country in NOVA’s four-part series, Making Stuff: Faster, Wilder, Colder, and Safer. Each of the four one-hour programs gave viewers a behind-the-scenes look at novel technologies poised to change our world—showing them how basic research and scientific discovery can hold the keys to transforming how we live. Making Stuff Season 2 (MS2) combined true entertainment with educational value, creating a popular and engaging series that brought accessible science into the homes of millions. NOVA’s goal to engage the public with such technological innovation and basic research extended beyond the broadcast series, including a variety of online, educational, and promotional activities: original online science reporting, web-only short-form videos, a new online quiz-game, social media engagement and promotion, an educational outreach “toolkit” for science educators to create their own “makerspaces,” an online community of practice, a series of nationwide Innovation Cafés, educator professional development, a suite of teacher resources, an “Idealab,” participation in national conferences, and specialized station relation and marketing. A summative evaluation of the MS2 project indicates that overall, these activities helped make a significant impact on the viewers, users, and participants that NOVA reached. The final evaluation conducted by Concord Evaluation Group (CEG) confidently concluded that the broadcast, website, and outreach activities were successful at achieving the project’s intended impacts. CEG reported that the MS2 series and website content were successful in raising awareness and sparking interest in innovation, and increased public awareness that basic research leads to technological innovation; this interest was also sustained over a six month period. Efforts to create an online community of practice were also successful: the quality of collaboration increased, and community members felt supported while using Maker pedagogy. These findings provide clear evidence that large-scale science media projects like MS2 are an effective means of “moving the needle” on attitudes about and excitement for science. NOVA’s broadcast audience and ratings have always indicated that a large portion of the population is interested in and engages with educational science media on a weekly basis. Yet these evaluation results provide the empirical evidence that beyond being capable of attracting, maintaining, and growing a dedicated group of citizens interested in science, these shows—with their diverse content provided on a variety of media channels—are capable of sparking new interest in science, raising public awareness of the importance of science, and maintaining and growing that interest over time. In a country where approximately a quarter of the population doesn’t know the earth rotates around the sun,1 roughly half still don’t accept evolution,2 and about 20% don’t think climate change is happening,3 the importance of these findings cannot be overstated. The success of MS2 suggests that large-scale media projects dedicated to and linked by coverage of scientific “big ideas” are an effective means of shifting public opinion on—and improving understanding of—science. REFERENCES 1, 2 National Science Foundation, Science and Engineering Indicators (2014). Chapter 7: Science and Technology: Public Attitudes and Understanding. 3 Leiserowitz, A., Maibach, E., Roser-Renouf, C., Feinberg, G., & Rosenthal, S. (2014) Climate change in the American mind: April, 2014. Yale University and George Mason University. New Haven, CT: Yale Project on Climate Change Communication.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Draft Electric Rule 21 Test Protocols for Advanced Inverter Functions

Disclaimer: The following document includes draft certification protocols and should not be viewed as a consensus-based performance standard. Distributed energy resources (DERs), such as photovoltaic (PV) systems, when deployed in a large scale, are capable of significantly influencing the operation of bulk and local power systems. Looking to the future, European and American stakeholders are working on standards to make it possible to manage the potentially complex interactions between DER and the power system. One of the jurisdictions considering modifications to the DER interconnection requirements is California. To determine what changes could improve electric grid reliability and allow greater penetrations of renewable energy, the California Public Utilities Commission (CPUC) and the California Energy Commission (CEC), in conjunction with consultant Frances Cleveland, convened the Smart Inverter Working Group (SIWG) in January 2013. The SIWG--composed of state agencies, utility engineers, national laboratories, manufacturers, trade associations, and advocacy groups--provided the CPUC a set of recommendations in early 2014 1 . The recommendations included specific advanced DER functions and interoperability requirements, along with a proposed timeline, for California to add new capabilities to grid-interconnected DER. On August 18, 2014 the three California Investor-Owned Utilities (IOUs)--Pacific Gas and Electric Company (PG&E), Southern California Edison Company (SCE) and San Diego Gas & Electric Company (SDG&E)--drafted a Advice Letter filing to the CPUC setting forth revisions to Electric Tariff Rule 21 to conform to the seven recommendations made by the Working Group 2 . After a comment period, the CPUC issued an update to the IOU recommendations 3 . At the time of this publication, there was no final legal ruling on the CPUC Rulemaking (R.) 11-09-011 ("Order Instituting Rulemaking on the Commission's Own Motion to improve distribution level interconnection rules and regulations for certain classes of electric generators and electric storage resources"). In the U.S., Nationally Recognized Test Laboratories (NRTLs) independently verify products to safety and functional standards. PV inverters are certified to Underwriters Laboratories (UL) Standard 1741 4 . However, new advanced inverter functions described in the SIWG and IOU proposals are not included in this standard, so there is a critical need to develop test protocols for these functions in preparation of a positive ruling by the CPUC. Through a California Solar Initiative Grant, Sandia National Laboratories (Sandia or SNL), Underwriters Laboratories (UL), Electric Power Research Institute, Inc. (EPRI), Xanthus Consulting, SunSpec Alliance, Loggerware, and utility and PV inverter manufacturers have collaborated to draft this certification protocol for the Rule 21 SIWG Phase 1 advanced inverter functions. This report also includes test procedures for Phase 2 and Phase 3 functions that will be demonstrated later in the CSI4 project. This collaborative effort was performed in close junction with the UL 1741 Standards Technical Panel (STP) working group. This document represents a snapshot of the draft testing protocols at the time of publication and not a consensus certification protocol for advanced inverters. 1 California Public Utilities Commission, "Recommendations for Updating the Technical Requirements for Inverters in Distributed Energy Resources, Smart Inverter Working Group Recommendations," Filed 7 Feb 2014. 2 J.J. Newlander, R.G. Litteneker, S.W. Walter, M. Dwyer, Joint motion of Pacific Gas and Electric Company (U 39 E), Southern California Edison Company (U 338 E) and San Diego Gas & Electric Company (U 902 E) regarding implementation of smart inverter functionalities, Rulemaking 11-09-011 Advice Letter, 18 July, 2014. 3 J.T. Sullivan, CPUC Rulemaking 11-09-011 Agenda ID #13460, 13 Nov, 2014. 4 Underwriters Laboratories Std. 1741 Ed. 2, "Inverters, Converters, Controllers and Interconnection System Equipment for use with Distributed Energy Resources," 2010.

42 ENGINEERING↗
DOE OSTI2021

Tunable Permanent Magnet Quadrupole Operating at Cryogenic Temperatures for Accelerators

The project objective is to develop a compact and tunable quadrupole using Electron Energy Corporation (EEC)’s PM materials for cryogenic accelerator applications. To achieve this objective, EEC and SLAC National Accelerator Laboratory (SLAC) will collaborate to develop a cost-effective quadrupole and optimize the conventional manufacturing process. Based on previous experience, EEC designed an innovative field adjustment capability using tuning magnets which is able to achieve all the requirements for SLAC’s cold copper collider (C3 ) application. These novel ideas enable us to develop a compact and tunable quadrupole magnet superior to the current designs. Our approach is to leverage EEC's over 50 years of experience in magnet manufacturing and SLAC’s beamline test capabilities.

42 ENGINEERING↗
DOE OSTI2026

Draft Impacts: Modeling and Lab Validation (CRADA Final Report)

Chimney draft is a significant source of variability in real-world wood heater performance, yet laboratory tests conducted for certification do not capture this variability. Because draft varies with climate, chimney height, and home conditions, a heater that performs well in the lab can perform quite differently when installed in a home. Until now, wood heater manufacturers and installers have lacked the tools needed to anticipate how draft will vary across real installations or to advise on corrective measures when draft is too low or too high. The goal of this project was to develop and validate an open-source draft prediction tool for cordwood heater chimney systems. Over 18 months, Lawrence Berkeley National Laboratory (LBNL) and the Hearth, Patio & Barbecue Association (HPBA) collaborated to build a physics-based, Python tool that predicts how chimney draft evolves during operation, from ignition through steady burning. HPBA convened a stakeholder group of manufacturers and venting experts who provided feedback throughout development. LBNL validated the tool against laboratory measurements from a catalytic and a non-catalytic cordwood heater operated across a range of chimney heights and room-pressure conditions.

42 ENGINEERING↗
DOE OSTI2018

ION Advanced Solvent CO 2 Capture Pilot Project

This final report to DOE/NETL presents all the work and tests performed during ION Engineering’s (ION) carbon dioxide (CO 2 ) capture pilot test campaign: “ION Advanced Solvent CO 2 Capture Project”. This project is comprised of three budget periods (BP): BP1 – Design of a 0.6 MWe system, BP2 – 0.5 MWe National Carbon Capture Center (NCCC) Testing Campaign, and BP3 – 12 MWe Technology Center at Mongstad (TCM) Testing Campaign. The program began in October 2013 and continued until December 2017. The campaign at NCCC, which took place from June to August of 2015, resulted in 1,116 operational hours where ~350 tonnes of CO 2 were captured from the 0.5 MWe coal-fired flue gas slipstream. The follow-up campaign at TCM took place from Oct 2016 to April 2017, where 2,775 hours of operation resulted in the capture of 14,820 tonnes of CO 2 , which is a cumulative of capturing CO 2 from the natural gas-fired Combined Heat and Power (CHP) plant, and a residue fluid catalytic cracker gas (RFCC) from Statoil at Mongstad. ION has conducted a thoughtful, comprehensive, and successful program in close collaboration with all its partners. CO 2 was successfully removed and captured for extended periods of time using three gas sources (NCCC Coal-fired Power plant, TCM CHP flue gas with and without CO 2 recycle, and TCM RFCC flue gas with air dilution) at various slipstream flows ranging from 0.5 MWe to 12 MWe. The data gathered on its solvent continues to strengthen the development of ION’s advanced solvent and positive track record in executing on-site test campaigns in highly industrialized settings. These existing pilot plants do not include the necessary process modifications that ION requires to obtain the lowest possible regeneration energy; processes such as a cold-rich bypass and intercooling, would allow for lowering the demonstrated specific reboiler duty. The resulting data was also used to validate the process model, and, in the absence of testing on a custom test rig specifically designed for ION’s advanced solvent, the results of the process model have shown specific reboiler duties under 2.5 MJ/kg CO 2 (1075 BTU/lb CO 2 ). When these regeneration energies are factored into the Techno-Economic Analysis (TEA), where ION’s technology is compared to the DOE/NETL BBS Case 12, which integrates a highly optimized and commercially available CO 2 capture technology, ION’s technology shows: 38% incremental reduction in capital cost of CO 2 capture; 28% incremental reduction in annual operating and maintenance costs of CO 2 capture; and $35-44 per tonne of CO 2 capture, which is a 20% to 40% reduction in cost of CO 2 capture. Throughout pilot testing, ION has confirmed its understanding of process improvements and analytics that will enable successful operation of its advanced solvent at significantly lower L/G circulation rates, packing heights and regeneration energies than MEA. ION has identified routes to further develop its technology and is looking forward to testing a fully optimized solvent and capture system in the near future.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Tailoring Fibre Structure Enabled by X-ray Analytics for Targeted Biomedical Applications

The rising interest in designing fibres via spinning techniques combining the properties of various polymeric materials into advanced functionalised materials is directed towards targeted biomedical applications such as drug delivery, wearable sensors or tissue engineering. Understanding how these functional polymers exhibit multiscale structures ranging from the molecular level to nano-, micro-and millimetre scale is a key prerequisite for their challenging applications that can be addressed by a non-destructive X-ray based analytical approach. X-ray multimodalities combining X-ray imaging, scattering and diffraction allow the study of morphology, molecular structure, and the analysis of nano-domain size and shape, crystallinity and preferential orientation in 3D arrangements. The incorporation of X-ray analytics in the design process of polymeric fibers via their nanostructure under non-ambient conditions (i.e. temperature, mechanical load, humidity…) allows for efficient optimization of the fabrication process as well as quality control along the product lifetime under operating environmental conditions. Here, we demonstrate the successful collaboration between the laboratory of Biomimetic Textiles and Membranes and the Center of X-ray Analytics at Empa for the design, characterisation and optimisation of advanced functionalised polymeric fibrous material systems.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Results of Modeling and Simulation Support to Specia Nuclear Material Handling Facility Operations - 16053

Newport News Shipbuilding (NNS) is the sole designer and provider of nuclear powered aircraft carriers and one of only two companies in the United States to build nuclear powered submarines. As part of the upkeep of aircraft carriers, the ships return to NNS once in their lifetime for a complex overhaul and to be refueled. In support of overhaul operations NNS maintains a state of the art Special Nuclear Material (SNM) handling facility. Due to the complex nature of the operations that occur within this facility, during the design and initial operation of the building NNS developed a facility simulation model to provide decision support during the project planning and operational phases. This tool allows users to experiment with process times, process order, equipment utilization, personnel utilization and spatial utilization. By capturing the planned operations, time distributions for operations, equipment sizes and uses and personnel requirements, the tool accurately reflects the planned use of the facility. This realism allows the user to experiment with any aspect of the facility, in a controlled and cost effective space, and determine how changes or potential delays may impact overall facility operations. Thus the model allows for rapid exploration of multiple scenarios to determine likely outcomes, allowing a user to identify risks well ahead of their realization and explore mitigation strategies in a controlled space, to determine the ideal path forward. The tool was successful during the initial operation of the facility in helping to identify and mitigate risks related to the complex operations occurring during SNM handling. The tool is now in use to support planning for the next series of operations that will occur within the facility. The initial operations the model supported occurred during the deactivation of the USS Enterprise, and future operation will focus on the overhaul of Nimitz class aircraft carriers. The NNS planning team is currently using the tool to assess potential risks and challenges that are identified as potentially impacting the schedule and timelines for these overhaul processes. In addition, the NNS development team is working to add new operational steps to the model, capturing work that is occurring near the facility, but which directly impacts the facilities operational abilities. In conjuncture with the engineering planning division, the NNS development team has run over 20 complex scenarios through the tool. The team has provided output from these scenarios to both NNS personnel and government representatives. To date the model has successfully supported the identification of several feasible paths to incorporate new processes, dictated by the work to support a overhaul vs a deactivation. The model also provides a spatial arrangement component that allows users to experiment with different equipment placement within the facility. Due to the fidelity of the model, arranging equipment with the spatial component allows a user to set up the facility in an experimental layout and run the processes inside the facility to determine if the layout will be feasible, or if it would impact operational capabilities. Additionally, the spatial component allows for visual collaboration between stakeholders to ensure all operational personnel are aware of the current and planned layout, and that they do not locate equipment or work stations in locations that would interfere with facility operations. The spatial component, in combination with the simulation component, has resulted in several documented improvements in process. These include: the identification of additional equipment which could be stored outside the facility, without impacting operations, to increase space; confirmation of the ideal placement of a large water tank; and identification of several risks related to planned equipment storage area, allowing the team to develop new plans and avoid realizing the risk. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Integrating Safety, Security, and Nuclear Operations for Advanced Reactors

The traditional separation between safety, security, and operations teams has created significant barriers to achieving optimal outcomes. When security considerations are introduced late in the design process, they often conflict with already-established architectural, operational, or engineering parameters. Retrofitting security measures can lead to increased costs, schedule delays, and compromises in security effectiveness. For instance, the need to retrofit physical barriers or surveillance systems often results in trade-offs that could have been avoided with earlier input from security professionals. Delayed integration can also affect regulatory processes and result in licensing delays. Security reviews conducted at later stages frequently identify gaps that necessitate significant redesign efforts, impacting not only scope, schedule, and budget, but also adding risk and lowering stakeholder confidence in the project. This paper aims to address these challenges by identifying practical opportunities for integrating security considerations seamlessly with design and operations teams throughout the entire lifecycle of nuclear facilities—from conceptual design to commissioning and beyond. The research emphasizes the value of early and continuous collaboration among stakeholders to ensure that security measures are robust, operationally effective, and cost-efficient. By examining case studies, analyzing past incidents, and leveraging best practices from other high-security industries, this study highlights actionable strategies for bridging the gap between safety, security, and operations teams.

Zineddin, Dr. Z. [ORNL] (ORCID:0009000848740725)↗
DOE OSTI2017

Validation of Material Models For Automotive Carbon Fiber Composite Structures Via Physical And Crash Testing (VMM Composites Project)

As automotive fuel economy requirements increase, the push for reducing overall vehicle weight will likely include the consideration of materials that have not previously been part of mainstream vehicle design and manufacturing, including carbon fiber composites. Vehicle manufacturers currently rely on computer-aided engineering (CAE) methods as part of the design and development process, so going forward, the ability to accurately and predictably model carbon fiber composites will be necessary. If composites are to be used for structural components, this need applies to both, crash and quasi-static modeling. This final report covers the results of a five-year, $6.89M, 50% cost-shared research project between Department of Energy (DOE) and the US Advanced Materials Partnership (USAMP) under Cooperative Agreement DE-EE-0005661 known as “Validation of Material Models for Automotive Carbon Fiber Composite Structures Via Physical and Crash Testing (VMM).” The objective of the VMM Composites Project was to validate and assess the ability of physics-based material models to predict crash performance of automotive primary load-carrying carbon fiber composite structures. Simulation material models that were evaluated included micro-mechanics based meso-scale models developed by the University of Michigan (UM) and micro-plane models by Northwestern University (NWU) under previous collaborations with the DOE and Automotive Composites Consortium/USAMP, as well as five commercial crash codes: LS-DYNA, RADIOSS, VPS/PAM-CRASH, Abaqus, and GENOA-MCQ. CAE predictions obtained from seven organizations were compared with experimental results from quasi-static testing and dynamic crash testing of a thermoset carbon fiber composite front-bumper and crush-can (FBCC) system gathered under multiple loading conditions. This FBCC design was developed to demonstrate progressive crush, virtual simulation, tooling, fabrication, assembly, non-destructive evaluation and crash testing advances in order to assess the correlation of the predicted results to the physical tests. The FBCC was developed to meet a goal of 30-35% mass reduction while aiming for equivalent energy absorption as a steel component for which baseline experimental results were obtained from testing in the same crash modes. The project also evaluated crash performance of thermoplastic composite structures fabricated from commercial prepreg materials and low cost carbon fiber sourced from Oak Ridge National Laboratory. The VMM Project determined that no set of predictions from a CAE supplier were found to be universally accurate among all the six crash modes evaluated. In general, crash modes that were most dependent on the properties of the prepreg were more accurate than those that were dependent on the behavior of the joints. The project found that current CAE modeling methods or best practices for carbon fiber composites have not achieved standardization, and accuracy of CAE is highly reliant on the experience of its users. Coupon tests alone are not sufficient to develop an accurate material model, but it is necessary to bridge the gap between the coupon data and performance of the actual structure with a series of subcomponent level tests. Much of the unreliability of the predictions can be attributed to shortcomings in our ability to mathematically link the effects of manufacturing and material variability into the material models. This is a subject of ongoing research in the industry. The final report is organized by key technical tasks to describe how the validation project developed, modeled and compared crash data obtained on the composite FBCC to the multiple sets of CAE predictions. Highlights of the report include a discussion of the quantitative comparison between predictions and experimental data, as well as an in-depth discussion of remaining technological gaps that exist in the industry, which are intended to spur innovations and improvements in CAE technology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Initial testing of wave energy powered UV-C LED anti-biofouling system (CRADA 523)

3newable is requesting technical assistance for laboratory testing at the Marine and Coastal Research (MCRL) Laboratory of a UV-C LED anti-biofouling system. Ocean observing sensors provide critical data sources from deployed buoys and other platforms at sea. However, in addition to the availability of reliable power sources, biofouling of sensors and instruments is a limiting factor for operation and maintenance of deployed instruments. In collaboration with the Woods Hole Oceanographic Institute Ocean Observatories Initiative, 3newable has developed a novel solution to overcome these challenges and extend the deployment period of buoy-mounted sensors. The 3newable system co-locates wave energy converters to supply UV-C LED anti-biofouling units on powered buoy arrays. MCRL staff will implement an experiment to evaluate the efficacy of 3newable’s device under test for inhibiting growth of organisms on test coupons in a flow through seawater tank.

42 ENGINEERING↗
DOE OSTI2019

A Joint Experimental/Computational Study of Non-Idealities in Practical Rotating Detonation Engines. Final Project Report, 10/2015 - 09/2020

The overall goal of this work is to understand non-ideal effects in practical rotating detonation engines (RDEs) that impede the realization of theoretical detonation cycle efficiencies. The main limitations in RDE operability and performance are associated with practical design considerations, where non-idealities, such as incomplete mixing, fuel leakage, secondary deflagration, instabilities and geometry-dependent effects, reduce the effectiveness of the detonation-based compression cycle. The goal of this work is to take a fundamental point of view, and use detailed experiments and simulations to understand non-ideal effects, their contribution to loss in pressure gain, and RDE operability limitations. Current research is mainly focused on design and overall operability of RDEs. Our approach is instead to look at the physics of basic processes occurring in RDEs. In particular, we consider processes associated with non-idealities and we use a combination of laser and non-laser diagnostics and large eddy simulation/direct numerical simulation computations to investigate these underlying phenomena. By advancing the fundamental science of detonation wave propagation in RDE flowfields, and subject to non-ideal conditions, will enable design to progress more rapidly. This work is a collaborative work involving experiments, simulations and external domain experts to understand the physics behind RDEs and non-idealities. Through collaboration between experimentalists and modelers, we have developed targeted experiments to investigate fundamental aspects of the operation of an RDE. Furthermore, we have developed advanced combustion models that account for non-ideal effects in the operation of an RDE and are able to capture the complexities of realistic RDE configurations. We conduct detailed physical and computational experiments to investigate the flame structure ahead and behind detonation fronts in the presence of non-uniform or incomplete mixing, leakage and secondary combustion. We use optical and laser diagnostics to identify the structure of the detonation wave. We consider different working parameters, such injection scheme, geometry, flow rates and equivalence ratios. We brought in DNS/LES capabilities to RDE design by specifically incorporating detailed kinetics and pressure-sensitive combustion physics, thus improving upon current practice based on an Euler equations description that do not take into account viscous effects, while the combustion process is introduced using an induction time based global ignition model. These current models lack the capability of capturing non-ideal mixing and fuel stratification effects — limitations that models and analysis developed in this work have been reduced. Furthermore, the significant changes in pressure within the domain due to the detonation requires combustion models with time-varying pressure effects. In this regard, using DNS with detailed chemistry, and developing LES-based combustion models for complex geometries with detonation wave has enable to understand some of the underlying phenomena controlling the operation of these devices. The main objectives developed by the project are the following ones: Objective 1. Develop canonical and operational RDE configurations, as well as imaging-based diagnostics for understanding fuel stratification, leakage, deflagration and detonation structure under non-ideal conditions in RDEs. Objective 2. Develop detailed computational tools for studying detonation wave propagation processes in RDEs. Objective 3. Develop a comprehensive picture of the fundamental physics governing non-idealities and how they impact RDE performance and operability from both experiments and simulations.

03 NATURAL GAS↗