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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 163 records · Page 9

A Planar-Cavity Receiver Configuration for High-Temperature Solar Thermal Processes: Preprint

Next generation concentrating solar thermal power (CSP) and novel solar thermochemical systems using concentrating solar thermal (CST) energy require high operating temperatures exceeding those of traditional nitrate-salt CSP systems. Particle-based systems are attractive for next-generation CSP and CST applications owing to high-temperature stability of inert silica- or alumina-based particulate materials, the lack of low-temperature freezing concerns that limit molten salt and/or molten metal heat transfer media, and cost-effective thermal storage using low-cost particulate and containment materials. Open-cavity falling particle receivers have many potential advantages, but face challenges pertaining to scalability, thermal loss, and particle loss through the open aperture, and are infeasible for chemical processes that require a low-oxygen ambient environment. Enclosed receiver configurations can be scalable, avoid particle loss when heating particles, and have potential for future chemical processes; however, particle-based heat transfer media provide substantially lower heat transfer rates than liquid media, and thus enclosed particle receiver designs require novel configurations to limit surface temperatures under the high incident solar flux concentrations necessary for high receiver thermal efficiency at high temperature. This paper introduces the novel planar-cavity enclosed particle receiver configuration in which arrays of planar surfaces are arranged into sub-vertical cavities. Large angles between the panel surface normal vectors and the aperture surface normal allow the incoming solar beam to distribute along the panel walls. Correspondingly, a high incident solar flux concentration at the cavity aperture produces substantially lower absorbed solar flux concentration on any panel wall. Sets of individual vertical cavities can be arranged to form a scalable receiver configuration.

cavity receiver↗

Moderator Considerations for Space Nuclear Power and Propulsion Systems

Nuclear reactors have the potential to provide high energy density to enable sustainable surface power and advanced propulsion methods needed for human exploration activities at the moon and mars. Current mission planning is surveying different reactor types for space power and propulsion application. Of these reactor types, the use of a moderator within the reactor can enable reduced enrichment, reduce overall fuel loadings, and minimize the critical size of the reactor compared to unmoderated reference systems. This proceeding summarizes some moderator materials identified for space reactor applications: zirconium hydride, yttrium hydride, beryllium, and beryllium oxide, and the unique design considerations inherent to surface power and nuclear thermal propulsion reactor designs. It was found that there are four key considerations during the moderator selection and design process: nuclear properties, thermophysical & mechanical properties, manufacture & readiness, and environmental compatibility. Surface power reactors can benefit from moderators which minimize overall system mass and are capable of surviving high temperature irradiation environments for years with little degradation. Nuclear thermal propulsion reactors can benefit from moderators which are capable of retaining structural integrity under multiple burns while being exposed to a wide temperature range (40 < T < 500+ K). Moderator materials which exhibit good stability under irradiation and high temperature operation, minimize fuel pitch, and are high readiness are desirable for near term implementation.

nuclear thermal propulsion↗

Exploration of Heat-Driven Ejector High-Temperature Heat Pumps

Heat-driven ejector heat pumps use a supersonic ejector as a thermo-compressor to replace the mechanical compressor. Supersonic ejectors have many advantages in high-temperature heat pump (HTHP) applications, including high operating temperature tolerance, no need for lubrication, low maintenance, and low cost. The coefficient of performance of ejector HTHPs could be improved by selecting binary fluids with unique thermodynamic properties. Although supersonic ejectors have been widely used in refrigeration systems, their application in spaces and water heating is limited. This study explores the theoretical potential of ejector HTHPs with a sink temperature of 100°C–130°C and a lift temperature of 10°C–30°C. Ejector HTHPs were evaluated with single-fluid ejectors (SFEs) and binary-fluid ejectors (BFEs). A comprehensive, geometry-free theoretical model of BFEs was developed to predict the theoretical maximum entrainment ratios. HFE7500 and R718 (water) were selected as working fluids for SFEs and BFEs. SFEs operating with R718 provided a higher coefficient of performance of ejector HTHPs than SFEs operating with HFE7500 and BFEs. This study preliminarily demonstrates the technical potential of ejector HTHP applications in recovering moderate-temperature heat sources

Wang, Pengtao↗

Thermoradiative Conversion for Space Power Systems

The thermoradiative cell is a new method for converting heat energy to electrical power, first detailed by Strandberg in 2015. The cell is structurally similar to a photovoltaic cell, in that it is a p-n junction semiconductor device, but thermodynamically operates in the reverse direction, converting the thermal dark current into electrical power by utilizing the recombination radiation from thermally-generated electron hole pairs to radiate waste heat to space. This technology may have application for space missions in converting thermal energy produced by a radioisotope source or from a nuclear reactor into power. The power and efficiency can be calculated as a function of bandgap in the detailed-balance case (the Shockley-Queisser limit), in which all of the thermal emissivity of the cell is due to the recombination of thermally generated electron-hole pairs, and all other recombination losses are ignored. The current produced is directly proportional to the recombination radiation, and thus the more thermally generated pairs, the higher the current. The voltage is proportional to the external bias. These two constraints allow optimization of the optimum bias point for maximum power, and allow calculation of the efficiency at maximum power point. Unlike photovoltaic cells, the maximum power operating point is not the same as the maximum efficiency point, and higher efficiency can be achieved at a higher (negative) bias in the ideal case. Incorporating non-ideal losses, however, shifts the maximum efficiency point toward lower bias. Since a thermoradiative cell operates by radiating directly to space, the current produced by a themoradiative cells will increase with the Stefan-Boltzman radiative efficiency; roughly the fourth power of the temperature. Thus, in contrast to a photovoltaic converter, the power produced is highest at high operating temperatures. Likewise, in contrast to conventional thermal conversion, high radiator temperature increases, rather than decreases the efficiency. Thus, the thermoradiative conversion may fill a mission niche in which small radiator size is required. The basic operation will be summarized, applications to space power discussed, and the requirements for further research outlined.

Photovoltaic Cell↗

Measurement Approach and Design of the CubeSat Infrared Atmospheric Sounder (CIRAS)

The CubeSat Infrared Atmospheric Sounder (CIRAS) will measure upwelling infrared radiation of the Earth in the MWIR region of the spectrum from space on a CubeSat. The observed radiances can be assimilated into weather forecast models and be used to retrieve lower tropospheric temperature and water vapor for climate studies. Multiple units can be flown to improve temporal coverage or in formation to provide new data products including 3D motion vector winds. CIRAS incorporates key new instrument technologies including a 2D array of High Operating Temperature Barrier Infrared Detector (HOT-BIRD) material, selected for its high uniformity, low cost, low noise and higher operating temperatures than traditional materials. The detectors are hybridized to a commercial ROIC and commercial camera electronics. The second key technology is an MWIR Grating Spectrometer (MGS) designed to provide imaging spectroscopy for atmospheric sounding in a CubeSat volume. The MGS has no moving parts and includes an immersion grating to reduce the volume and reduce distortion. The third key technology is an infrared blackbody fabricated with black silicon to have very high emissivity in a flat plate construction. JPL will also develop the mechanical, electronic and thermal subsystems for CIRAS, while the spacecraft will be a commercially available CubeSat. The integrated system will be a complete 6U CubeSat capable of measuring temperature and water vapor profiles with good lower tropospheric sensitivity. The CIRAS is the first step towards the development of an Earth Observation Nanosatellite Infrared (EON-IR) capable of meeting the replacement needs of the CrIS on JPSS.

Pagano, Thomas S.↗

Evolution of the nanoporous microstructure of sintered Ag at high temperature using in-situ X-ray nanotomography

Silver pastes sintering is a potential candidate for die bonding in power electronic modules. The joints, obtained by sintering, exhibit a significant pore fraction, thus reducing the density of the material compared to bulk silver. The mechanical properties (Young's modulus, yield strength and ultimate tensile stress) are then drastically altered. However, while careful analysis of the nanoporous structure has been reported in 2D, little is known about its quantitative spatial evolution during thermal aging and more specifically during temperature jumps endured by the assembly during operation. High temperature evolutions of the 3D nanoporous structure have been observed in-situ using a heater fitted into the beamline 6-2c at SLAC-SSRL. Segmentation of the porosity and subsequent statistical analysis of the tomographic dataset reveal a complex evolution of the porous nanostructure including growth, separation and coalescence at a constant density. Such an analysis provides insight into the microstructural evolution of sintered nanoporous Ag joints in-service.

36 MATERIALS SCIENCE↗

Tuning the external optical feedback-sensitivity of a passively mode-locked quantum dot laser

The external optical feedback-sensitivity of a two-section, passively mode-locked quantum dot laser operating at elevated temperature is experimentally investigated as a function of absorber bias voltage. Results show that the reverse-bias voltage on the absorber has a direct impact on the damping rate of the free-running relaxation oscillations of the optical signal output, thereby enabling interactive external control over the feedback-response of the device, even under the nearly resonant cavity configuration. The combination of high temperature operation and tunable feedback-sensitivity is highly promising from a technological standpoint, in particular, for applications requiring monolithic integration of multi-component architectures on a single chip in order to accomplish, for instance, the dual-objectives of stable pulse quality and isolation from parasitic reflections.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Design and testing of high-performance mini-channel graphite heat exchangers in thermoelectric energy recovery systems

Recent national energy usage studies by Lawrence Livermore National Laboratory in 2015 [1] show that there is approximately 59 Quads (1015 Btu’s) of waste thermal energy throughout various industrial, residential, power generation, and transportation sectors of the U.S. economy. Thermoelectric energy recovery is one important technology for recovering this waste thermal energy in high-temperature industrial, transportation and military energy systems. Thermoelectric generator (TEG) systems in these applications require high performance hot-side and cold-side heat exchangers to provide the critical temperature differential and transfer the required thermal energy. High performance hot-side heat exchangers in these systems are often metal-based due to requirements for high-temperature operation, strength at temperature, corrosion resistance, and chemical stability. However, the generally selected metal-based hot-side heat exchangers (i.e., Inconels, Stainless Steels) suffer from low thermal conductivity, high thermal expansion, and high density, which degrades their thermal performance, leads to high thermal-expansion-driven stresses, and creates relatively high mass/high volume (i.e., low power density) TEG systems that are then difficult to fabricate and integrate into viable energy recovery systems. This paper describes the design and testing of a new, high-temperature minichannel graphite heat exchanger designed for operation up to 500C that is a critical element of a high-power-density TEG power system for aircraft energy recovery. This high-performance graphite heat exchanger represents a new state-of-the-art standard in high-temperature heat exchangers for TEG systems, which provides higher thermal transport, less thermal expansion at operation, lower system level stresses on TE components, and a lighter weight TEG system. This new heat exchanger creates a new design paradigm in TEG system design for terrestrial energy recovery and potential NASA technology infusion into terrestrial energy system applications. This paper will present and discuss the key heat transfer, pressure drop, pumping power analyses and design tradeoffs that created this unique design. Heat transfer and pressure drop modeling was performed with both empirical models based on known heat transfer and friction factor correlations and COMSOL thermal/fluid dynamic modeling of the graphite heat exchanger structure. We will also discuss resulting thermal transport and heat fluxes predicted at the TEG interface level. Heat exchanger performance testing was performed under simulated operating conditions and correlation with test data at the anticipated operating temperature conditions will be presented and discussed.

Shevade, Abhijit↗

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800 oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗

Microhole Test Data

Drilling results from the microhole project at the Sandia High Operating Temperature test facility. The project is seeking to help reduce the cost of exploration and monitoring of geothermal wells and formations by drilling smaller holes. The tests were part of a control algorithm development to optimize the weight-on-bit (WOB) used during drilling with a percussive hammer.

15 GEOTHERMAL ENERGY↗

Ten Year Operating Test Results and Post-Test Analysis of a 1/10 Segment Stirling Sodium Heat Pipe, Phase III

High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 yr) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described.

Rosenfeld, John, H↗

Particle-based high-temperature thermochemical energy storage reactors

Solar and other renewable energy driven gas-solid thermochemical energy storage (TCES) technology is a promising solution for the next generation energy storage systems due to its high operating temperature, efficient energy conversion, ultra-long storage duration, and potential high energy density. Experimental and theoretical studies suggest that the respective gravimetric and volumetric TCES energy storage densities vary from 200 to 3000 kJ kg –1 and 1–3 GJ m –3 . Solar radiation or heat generated from electric furnaces powered by renewable electricity can be stored in the form of chemical energy through endothermic reactions, while the stored chemical energy can be converted to thermal energy via an exothermic reaction when needed. The design of highly effective reactors requires a deep understanding of materials, thermodynamics, chemical kinetics, and transport phenomena. At time of writing, TCES reactors are yet to be deployed at commercially relevant scales, leaving a substantial gap between development efforts and commercial feasibility. Therefore, this review aims to examine the state-of-the-art design and performance of particle-based TCES reactors with different reactive materials. Fundamentals related to TCES reactive materials, reaction conditions, thermodynamics and kinetics, and transport phenomena are reviewed in detail to provide a comprehensive understanding of the reactor design and operation. Five major types of TCES reactors have been comprehensively reviewed and compared, including fixed, moving, rotary, fluidized, and entrained bed reactors. Most reported prototype reactors in the literature operate at lab scale with thermal inputs below 40 kW, and scaled TCES reactors (e.g., at megawatt level) are yet to be demonstrated. The nominal reactor operating temperatures range from 300 to 1500 °C, depending on the selected chemistry, reactive material, and heat sources. To evaluate their designs, the reactors are assessed in aspects of performance, cost, and durability. Discrepancies in performance indicators of energy storage density, extent of reaction, and various energy efficiencies are highlighted. The scale-up of reactors and power block integration, which hold the key to the successful commercialization of TCES systems, are critically analyzed. Furthermore, advanced materials (both reactive materials and ceramic reactor housing materials), effective particle flow control, advanced modeling tools, and novel system design may bring significant improvement to the energy efficiency, storage density and cost competitiveness of particle-based TCES reactors.

25 ENERGY STORAGE↗

High-temperature ceramics for automobile gas turbines

The employment of the high operational temperatures makes it necessary to use, for the construction of the turbines, ceramic materials such as silicon nitride or silicon carbide. Investigations concerning the development of turbine components made of such materials are conducted by a German automobile manufacturer and the ceramics industry. The current status of these investigations is reviewed. Flame tubes and guide-vane rings have successfully passed tests lasting 20 hours. Prototype turbine wheels have withstood the effects of peripheral speeds of 450 m/s. They also showed resistance to thermal shocks which were as high as 6-0 K/s.

Walzer, P.↗

A molten battery consisting of Li metal anode, AlCl3-LiCl cathode and solid electrolyte

High performance rechargeable batteries are crucially needed to address the demands of grid-scale stationary energy storage. High temperature battery systems, such as Na-S battery, Na-NiCl2 battery (ZEBRA battery) and liquid metal electrode (LME) battery, exhibit advantages like high power density and high cyclic stability, but also suffer from the high operating temperature. We recently invented new concept of molten lithium metal batteries, consisting of liquid lithium anodes, alloy (Sn, Bi, Pb) liquid cathodes and lithium ion conductor as solid electrolytes. Here we demonstrate a molten metal chloride battery that operates at a relatively low temperature of 210 °C. The battery has been designed to include molten (AlCl3-LiCl) cathode, solid electrolyte (garnet-type Li6.4La3Ta0.6Zr1.4O12 (LLZTO) ceramic tube) and molten lithium anode. The assembled AlCl3-LiCl||LLZTO||Li full cell has an average discharge voltage of 1.55 V and energy efficiency of 83% and has been successfully cycled for 100 cycles (800 h) without capacity fade. The theoretical specific energy of cell is 350 Wh/kg and the estimated cost is $11.6/kWh based on the weight of electrode materials. Considering the high performance, high safety, low operating temperature and low cost of raw materials, this novel type of molten-electrode battery system opens up new opportunities for stationary energy storage.

25 ENERGY STORAGE↗

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗

Refractory Solar Selective Coatings

This three-year project worked towards developing high-performance selective receiver coatings for concentrated solar power (CSP) to meet the DOE SunShot 2020 goal of levelized cost of energy (LCOE) ≤6 ¢/kWhe. We exploited recent advances in photonic crystal fabrication and nanocomposite materials synthesis to manufacture coatings designed to withstand high operating temperatures in air (>800 °C) while maintaining a high solar absorptivity (≥95%) and low IR emissivity (≤10%). We engineered the selective receiver coatings at multiple length scales. In the 0.1-1 μm regime, the coating has a photonic crystal structure comprised of a periodic mesoporous array. This structure alters the photonic density of states to improve spectral selectivity while also mitigating thermal stress for improved lifetime. At the 1-10 nm scale, the coatings are composed of optically absorbing nanoparticles in a transparent matrix where the size, spacing, and composition of the nanoparticles are tailored to tune the optical properties for high visible absorption and low IR emittance - similar to a cermet, but with dramatically enhanced thermal stability. The photonic structure was fabricated by self-assembly from a nanoparticle suspension followed by infiltration using atomic layer deposition (ALD). The nanophase composite results by combining the ALD processes for a metal and a metal oxide.

14 SOLAR ENERGY↗

Lead salt diode lasers and development of tunable solid state lasers for remote sensing

Extensive studies of the output characteristics of single quantum well lead-telluride lasers developed at the General Motors Research Laboratories were carried out. Threshold currents, output powers and line structures were measured as a function of temperature. Very low-current lasing thresholds, record high operating temperatures and over 30% tuning ranges were achieved. Excellent reproducibilities, good far-field patterns and reasonable linewidths (approx. 500 kHz) were found.

Freed, C.↗