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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Manufacturing of magnesium/aluminum bimetallic ring components by friction stir assisted simultaneous forging and solid-state joining

Here, a bimetallic ring component is forged by a friction stir assisted forging (FS-forging). A cylindrical bimetallic blank, magnesium AZ31 cylinder (Mg core) tightly fitted inside an aluminum 6061-T6 tube (Al skin), is used. In the FS-forging, the frictional heat and stirring of rotating tool forge the blank into a desired shape, while simultaneously generate a solid-state joint between the Mg core and the Al skin, without additional external heating, as confirmed by the microstructural analysis and mechanical tests. The microstructural analysis also shows that the characteristics of the solid-state joint can be different depending on the process parameters.

42 ENGINEERING↗
DOE OSTI2025

Current-Activated Reactive Ultrafast Joining (CARUJ)

We have demonstrated Current Activated Reactive Ultrafast Joining (CARUJ) as a novel approach for rapid fabrication of similar and dissimilar materials, such as ceramic-ceramic and ceramic-metal joint assemblies. The CARUJ technology utilizes resistive heating of carbon-based materials to apply localized heat at, (through or around) joint zones at rates of 10 1 -10 2 ˚C/min, enabling joining at time scales considerably shorter (several minutes as opposed to hours) than conventional approaches for similar systems. Herein, we present our findings while evaluating the CARUJ concept. Three methods of heat application were evaluated: (i) using carbon joule heating elements to apply heat directly through the joint interface; (ii) using flexible joule heating elements to locally apply heat around the assembly interface; and (iii) non-contact heating of the joint assembly using inductive power. Schemes (ii) and (iii) proved to be the most effective in producing mechanically sound reliable joints. We demonstrated single-step fabrication of dense SiC-SiC joints with a Si- SiC interface using minimal pressure (1–2 MPa) in under 30 minutes. Measured average joint strengths of about 15 MPa are initially achieved for joined bodies when tested in single lap offset (SLO) compressive shear, while tuning of the interfacial composition along with a reduction in interlayer thickness, results in improved joint strengths of approximately 43 MPa. We further demonstrated SiC-SiC joining using Active Brazing Alloys (ABAs) proof of concept joining of tubular geometries. The versatility of CARUJ is demonstrated by utilizing non-contact heating via induction, to join dissimilar materials systems of SiC, SS316 and MAX phase ceramics with ABA interlayers. The localized and rapid heat application realizes a versatile material joining technique that can be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Testing the DAE LLRF system with a PIP-II SSR2 Cavity

The PIP-II linac is an international collaboration project with in kind contributions of key subsystems from multiple countries including India (DAE). In the research and development phase of the project, the LLRF and resonance control systems were jointly developed by BARC and Fermilab and were delivered to Fermilab for testing and validation. Initial testing of the LLRF system was carried out using Fermilabs analog cavity emulator. Following successful emulator testing, the LLRF system was deployed at STC on a PIP-II 325 MHz SSR2 cavity. The cavity was operated in both SEL and GDR modes at a gradient of 5 MV/m. The results of the testing are presented here.

Nasery, Radhika [Bhabha Atomic Res. Ctr.]↗
DOE OSTI2025

Convergence of Cloud Droplet Spectral Relative Dispersion During Entrainment‐Mixing Based on Particle‐Resolved Direct Numerical Simulations

Entrainment-mixing processes critically impact cloud microphysical properties, but their effects on the relative dispersion (d) of cloud droplet size distributions (CDSDs) remain elusive. A direct numerical simulation model is initialized with different CDSDs to fill the gap. These results show that d decreases for broad CDSDs and increases for narrow ones, ultimately converging to approximately 0.5 regardless of initial CDSDs during the evaporation-dominated mixing stage. The supersaturation fluctuation and the shape of CDSDs jointly influence the convergence behavior of d. Further sensitivity tests show that the initial microphysical/dynamical/thermodynamical conditions exert negligible effects on the final converged value of d but affect the convergence rate (k). The k generally increases with increasing droplet number concentration and dissipation rate, and increases with decreasing liquid water content, relative humidity of entrained air, and mixing fraction of cloudy air. A conceptual model with two timescales is proposed; k and the timescales are negatively correlated, meaning that slow mixing and/or evaporation process results in slow convergence of d. In conclusion, this finding provides an important reference for improving understanding and parameterization of d during the entrainment-mixing processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Improving Experience Beyond the Ride: Joint Assignment and Repositioning for Rideshare

In this study, a novel joint assignment and repositioning strategy is designed, implemented, and tested in a simulated traffic environment. The strategy addresses limitations of previously constructed rideshare repositioning algorithms by integrating the consideration of rider pooling into the optimization. By considering pooling, the strategy can minimize excess vehicle movement and increase riders' use of pooled services over a zonal-flow-based repositioning strategy and a fleet operating with no repositioning at all. The new strategy can increase pooling by up to 2.3% compared to no repositioning in a large region, and up to 0.1% in a small region, without compromising overall fleet revenue. Additionally, compared to a baseline, flow-based repositioning strategy, the new strategy can reduce empty vehicle travel by up to 30% in the larger region, and 2.1% in the smaller simulated area.

Paul, Joseph↗
DOE OSTI2022

Tribological studies of a novel high-performance aromatic thermosetting copolyester containing carbon nanotubes for artificial hip joints

A high-performance aromatic thermosetting copolyester containing multi-walled carbon nanotubes (ATSP-MWNTs) was synthesized, characterized, and tribologically tested against cobalt-chromium-molybdenum (CoCrMo) alloy) as a potential replacement for ultra-high molecular weight polyethylene (UHMWPE) in artificial joints. By investigating the tribological properties of ATSP-MWNTs, crosslinked UHMWPE vs CoCrMo alloy, it was found that ATSP-MWNTs exhibited a lower and more stable friction coefficient and negligible wear. Further, unlike the case of ATSP-MWNTs, an obvious wear was present for UHMWPE. It is believed that transfer films in ATSP-MWNTs help to stabilize and decrease friction and wear. In addition, large and aggregated particles of UHMWPE seem to contribute to an increase in friction and wear.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Washington Clean Energy Fund: Energy Storage System Consolidated Performance Test Results

This report provides an overview of test results for four energy storage systems funded under the Washington Clean Energy Fund deployed at three utilities in Washington State. Integration of energy storage into the U.S. grid has been gathering momentum across the industry, especially as penetration of power generated by renewable resources increases. Several states have storage procurement targets to deal with a variety of issues, such as afternoon total system load ramping requirements, frequency regulation/control, and integration power generated from by renewable resources. This report presents the performance test results for battery energy storage systems (BESS) funded by the Washington Clean Energy Fund (CEF) 1 Program ($\$$14.3 million in state funding supporting a total investment of $\$$43 million). For each project, the technical attributes of the BESS were tested, defined, and evaluated in detail. These projects were funded jointly by Avista, the Snohomish Public Utility District (SnoPUD), Puget Sound Energy (PSE), the Washington CEF, and the U.S. Department of Energy Office of Electricity Delivery and Energy Reliability (DOE-OE).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Magnetic and Mechanical Analysis of a Large Aperture 15 T Cable Test Facility Dipole Magnet

The US Department of Energy (DOE) Office of Science (SC), is funding a large bore “Cable Test Facility Magnet” for testing advanced cables and inserts in high transverse field. This is a joint effort between the Office of High Energy Physics (HEP) and the Office of Fusion Energy Sciences (FES). The background field magnet for this facility is being developed at Lawrence Berkeley National Laboratory (LBNL) while the cryostat and test facility will be located and operated by Fermi National Accelerator Laboratory (FNAL). The Nb 3 Sn dipole magnet, which will provide the transverse background field, is designed to generate a field of 15 T in a 100 × 150 mm bore at 1.9 K. The conceptual design of a block-type dipole with flared ends and a structure based on key-and-bladder technology will be introduced. The results of the magnetic and mechanical analysis will be presented.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

RIA Testing Program for ATF

Presentation on the RIA Testing Program for ATFs at TREAT for the 11th Annual EPRI/DOE/INL Joint Workshop on Accident Tolerant Fuel

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Uncertainty-Informed Operation Coordination in a Water-Energy Nexus

The widespread deployment of smart heterogeneous technologies and the growing complexity in our modern society calls for effective coordination of the interdependent lifeline networks. In particular, operation coordination of electric power and water infrastructures is urgently needed as the water system is one of the most energy-intensive networks, an interruption in which may quickly evolve into a dramatic societal concern. This paper develops a novel analytic for uncertainty-aware day-ahead operation optimization of the interconnected power and water systems (PaWS). Joint probabilistic constraint (JPC) programming is employed to capture the uncertainties in wind resources and water demand forecasts. The proposed integrated stochastic model is presented as a non-linear non-convex optimization problem, where the non-linear hydraulic constraints in the water network are linearized using piece-wise linearization technique, and the non-convexity is efficiently tackled with a solution methodology to convert the proposed model with JPCs to a tractable mixed-integer linear programming (MILP) formulation that can be quickly solved to optimality. Here, the suggested framework is applied to a 15-node commercial-scale water network jointly operated with a power transmission system using a modified IEEE 57-bus test system. The numerical results demonstrate the of the proposed stochastic framework, resulting in cost reduction (13% on average when compared to the traditional setting) and energy saving of the integrated model under different realizations of uncertain renewable energy sources (RESs) and water demand scenarios. Additionally, the scalability of the proposed model is tested on a modified IEEE 118-bus test system connected to five water networks.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer

A novel single pass friction stir dovetailing (FSD) was developed to join thick plate AA7099 to Ni-Cr-Mo steel in a lap configuration through the use of an AA6061 butter layer. The butter layer approach can be shown to significantly reduce interfacial failures by inhibiting the formation of brittle Fe–Al intermetallic compounds (IMCs) which are typically formed during conventional friction stir welding (FSW) of AA7099 directly to steel. This study evaluates the strength and microstructural evolution of the aluminum/steel joint interface between single pass FSD of AA7099/AA6061(butter)/steel fabricated using three different FSD tool configurations. The butter layer was achieved by placement of a free-floating strip of AA6061 within the dovetail groove that was pre-machined in the steel substrate. Friction stir welding was then used to simultaneously join the thick plate AA7099, the AA6061 strip and the AA7099 in a single weld pass. To optimize the joining process, three different pin geometries (full thread, half smooth/half thread, no thread) were evaluated; it was demonstrated that the half smooth/half thread tool produced the strongest weld joint due to the absence of a Zn rich layer at the Al/steel interface. The efficacy of this unique processing technique was tested using lap shear tensile testing as well as high resolution transmission electron microscopy (TEM). A discussion of the new FSD technique, joint configurations, and process parameters are provided along with joint microstructural analyses and mechanical performance.

Olszta, Matthew J.↗
DOE OSTI2025

A New Probability Table Methodology with Covariances on Probability Tables

Through this work, we test a new methodology of evaluating probability tables informed by a combination of physics models and experimental data. This methodology uses generalized least squares to produce a joint mean and covariance for average cross sections and probability tables. This methodology has been tested and validated using total Monte Carlo. Attempts were made to parameterize the probability table using a formulation provided in. Although the normal inverse Gaussian fit was successful for the total cross section probability distribution, the rational-function fit to the capture, inelastic, and fission cross sections was unsuccessful due to time constraints.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Design and Development of a Robotic Exoskeleton Device for use in Glove Boxes - 20374

Glovebox operators in nuclear facilities often operate under radioactive environment and typically perform monotonous, dull and repetitive work. This can result in muscle fatigue leading to increased levels of accidents. Current research work aims in assisting the glovebox operators by designing a novel upper limb exoskeleton device to reduce injuries and increase worker efficiency. Almost none of the commercially available hand and upper body exoskeletons are directly suitable for use in gloveboxes. This explains the novelty of the present work in developing a wearable powered robotic exoskeleton device. The device consists of electronics, motors and spring systems mounted on adjustable plates and is supported by a stationary frame behind the worker. The device is intended to be portable and adjustable according to the operator height. The elbow has a flexion movement assisted with motor control by way of a Bowden cable system. The system is floated on a spring and pulley combination that allows for extra safety and smoothness of operation. The end points are fixed near the pivot points to help minimize unwanted movement/torque. The extension movement of the upper and lower arm are assisted by gravity and a counter spring. The shoulder and upper arm movement are held in a neutral position with a spring system for counter balance allowing small movements within the glovebox. This initial concept considers only the vertical movement of the arm. The abduction and adduction movement will not be assisted or impeded by the over shoulder plate or at the forearm plate allowing for full range of motion. Several glovebox aspects such as the level of task assistance, ergonomic design, minimum hindrance in dexterity/operator movements and tear resistance for hazardous safety reasons will be considered in the design of the exoskeleton. Computer models will be simulated to test the load levels and stress conditions on the exoskeleton to enhance the designs. The exoskeleton focusses on major muscular involvement reduction through weight offset and active assistance with minimal parts and hence the device is derived with several joint links and contains both passive and active joints. The paper details the various stages in the design development and prototype testing of the exoskeleton device. Upon successful prototype device development, human testing will be conducted in a replica of the SRS-235F hot cell facility constructed at FIU-ARC. The final stage of the project will be potential testing/deployment of the exoskeleton device in one of the glovebox facilities in Savannah River Nuclear Waste site. (authors)

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

Gripper Test Assembly Status of Fabrication and Assembly Report – FY2023

The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

36 MATERIALS SCIENCE↗
DOE OSTI2020

TA-55 Forensic Support Operations Cross-Training Exercise

As part of the annual FBI/LANL training schedule, a joint training exercise was conducted during the week of 10FEB2020 with FBI HEAT members and LANL Fissile Material Handlers (FMHs). The joint training exercise was conducted in a non-radiological area to reduce cost and ensure the test object would not be contaminated. The exercise test object was fabricated by LANL using surrogate materials to represent an object containing Special Nuclear Material (SNM). Working with Jim Blankenship and Kevin Swearingen, functional requirements of the test object included the following: unclassified, disassembly (to include screws), and moderately heavy. To meet the objectives, the test object was fabricated by welding a custom aluminum box (8” x 8” x 12”) with a lid which was secured by four (4) screws. The custom box housed a track and field shot put (16 lbs.) that was anchored by a hose clamp. The intent of the training was to disassemble the test object and conduct traditional forensic determinations on the parts. This lessons learned report documents all of the associated aspects related to the joint training effort.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Measurement of crack length in width tapered beam experiments

The width tapered beam method for measuring fracture toughness has been contemplated for use in measuring the adhesion of photovoltaic materials, is promoted by it being a viable method for use directly on modules rather than to engineered test specimens. However, precise determination of crack length is often difficult as failure often involves tendril formation, cavitation voids, and other plastic deformation at the crack front in addition to obfuscation by opaque materials. Because fracture energy varies as the square of crack length, imprecise crack tip length results in large measurement uncertainties. In this work, we develop a method to estimate the crack tip length using the relationship between the applied force and the displacement of the load frame. The crack tip is determined for every data point and can be defined from a calibration curve related to the amount of energy put into the beam, or from a theoretically idealized estimation. Once a calibration curve is set up and the equations programmed, the fracture energy as a function of position on the newly formed crack interface can be accurately estimated. The test additionally provides much easier analysis and insight into the joint failure through more precise knowledge of fracture toughness at each de-bonded area.

42 ENGINEERING↗
DOE OSTI2024

Galaxy bias in the era of LSST: perturbative bias expansions

Upcoming imaging surveys will allow for high signal-to-noise measurements of galaxy clustering at small scales. In this work, we present the results of the Rubin Observatory Legacy Survey of Space and Time (LSST) bias challenge, the goal of which is to compare the performance of different nonlinear galaxy bias models in the context of LSST Year 10 (Y10) data. Specifically, we compare two perturbative approaches, Lagrangian perturbation theory (LPT) and Eulerian perturbation theory (EPT) to two variants of Hybrid Effective Field Theory (HEFT), with our fiducial implementation of these models including terms up to second order in the bias expansion as well as nonlocal bias and deviations from Poissonian stochasticity. Here, we consider a variety of different simulated galaxy samples and test the performance of the bias models in a tomographic joint analysis of LSST-Y10-like galaxy clustering, galaxy-galaxy-lensing and cosmic shear. We find both HEFT methods as well as LPT and EPT combined with non-perturbative predictions for the matter power spectrum to yield unbiased constraints on cosmological parameters up to at least a maximal scale of k max = 0.4 Mpc -1 for all samples considered, even in the presence of assembly bias. While we find that we can reduce the complexity of the bias model for HEFT without compromising fit accuracy, this is not generally the case for the perturbative models. We find significant detections of non-Poissonian stochasticity in all cases considered, and our analysis shows evidence that small-scale galaxy clustering predominantly improves constraints on galaxy bias rather than cosmological parameters. These results therefore suggest that the systematic uncertainties associated with current nonlinear bias models are likely to be subdominant compared to other sources of error for tomographic analyses of upcoming photometric surveys, which bodes well for future galaxy clustering analyses using these high signal-to-noise data.

79 ASTRONOMY AND ASTROPHYSICS↗