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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Enabling Digital Image Correlation for Deployment in the Hot Fuels Examination Facility

Digital image correlation (DIC) is a non-contact image-based technique for displacement and strain measurement. It is also a full-field method that can provide excellent spatial resolution. DIC has been widely used for measurements in many styles of mechanical tests and is desirable in part because of this flexibility to measure nearly any material across a range of time and length scales. Its ability to measure localized strain for tests and in environments not accessible to other strain measurement techniques makes it an ideal option for several mechanical test cases that exist in hot cell facilities such as the Hot Fuel Examination Facility (HFEF) at the Idaho National Laboratory (INL). However, DIC has not been demonstrated at HFEF, and several barriers to implementation in the hot cell environment exist. This report outlines the possible paths for deploying DIC at HFEF, weighing the technical advantages and risks with each path. It also discusses the steps which must be taken to add this capability to the suite of post-irradiation examination (PIE) techniques available at HFEF. Finally, it concludes with recommendations for the best method to perform DIC at the facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A Hot‐Swappable, Fault‐Tolerant, Modular Power Converter System for Solar Photovoltaic Plants

The performance metrics of the state-of-the-art commercial solar inverters, such as system cost, operation and maintenance (O&M) cost, service life, reliability, maintainability, and power density are much lower than the target metrics needed to achieve SunShot’s 2030 levelized cost of energy (LCOE) goals. To overcome the shortcomings of the existing solar inverters, this project proposed a novel Hot-Swappable, Fault-Tolerant, Modular Power Converter (HSFT-MPC) concept for solar photovoltaic (PV) plants and proved the concept through the design, fabrication, and laboratory test validation of a single-phase HSFT-MPC prototype. The HSFT-MPC has the following distinct advantages over the state-of-the-art: 1) elimination of harmonic/ electromagnetic interference (EMI) filter in the inverter stage due to the novel topology, 2) lower system cost and higher power density due to the modular design, elimination of harmonic/EMI filter, and lower cooling requirement, 3) higher efficiency due to lower switching frequencies, 4) higher reliability and longer (50 years) service life due to simpler cooling and fault tolerance capability, 5) easier installation, lower O&M cost, and improved maintainability due to the modular design and hot-swappable power electronic building blocks (PEBBs), and 6) improved manufacturability due to the modular design. This project developed a single-phase HSFT-MPC prototype with 25kW nominal output power, 2.4kV, 60Hz nominal AC output, lower than 5% AC output voltage total harmonic distortion, over 5 kW/L inverter power density, and 99.4% inverter peak efficiency, being tolerant to failure of single and multiple PEBBs, and capable of hot swapping of the failed PEBB(s). The HSFT-MPC enables uninterruptable operation of the solar PV plant when failure of single or multiple PEBBs or PV modules occurs. Compared with the existing solar inverters in the market, the HSFT-MPC is expected to reduce the inverter failure-caused downtime and energy losses of solar PV plants by more than 60% and 50%, respectively. Project findings have been presented at major conferences in the field and published in peer-reviewed papers, which added new knowledge to the field of power electronics for solar PV systems. A minicourse on Solar PV Systems was developed for outreach activities. The minicourse will help attract young individuals to the renewable energy profession which has a significant talent shortage. The HSFT-MPC is expected to overcome all of the shortcomings of the state-of-the-art solar inverters in terms of cost, efficiency, service life, reliability, maintainability, and manufacturability targets needed to achieve SunShot’s 2030 LCOE goals. Therefore, the proposed HSFT-MPC concept has the great potential to disrupt the current solar inverter market. This project created a pathway towards industry adoption of the HSFT-MPC to help achieve 50-year service life solar PV systems. Since the solar PV plants using the HSFT-MPC will feature with higher reliability, longer service life, and easier maintenance, they are particularly useful for the rural areas with underserved populations that demand reliable and affordable clean electricity. The outcomes of the project have the strong potential to address national needs in the field of renewable energy to reduce CO 2 emissions from the electricity sector, reduce imports of energy from foreign sources, and improve energy security, efficiency, and sustainability. Since electricity is used in almost all of society’s sectors, the outcomes of the project will benefit various sectors of society and economy.

14 SOLAR ENERGY↗
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limtis. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Smaller than Expected Bright-spot Offsets in Spitzer Phase Curves of the Hot Jupiter Qatar-1b

We present Spitzer full-orbit thermal phase curves of the hot Jupiter Qatar-1b, a planet with the same equilibrium temperature—and intermediate surface gravity and orbital period—as the well-studied planets HD 209458b and WASP-43b. We measure secondary eclipse depths of 0.21 ± 0.02% at 3.6 μm and 0.30 ± 0.02% at 4.5 μm, corresponding to dayside brightness temperatures of 1542{sub −31}{sup +32} K and 1557{sub −36}{sup +35} K, respectively, consistent with a vertically isothermal dayside. The respective nightside brightness temperatures are 1117{sub −71}{sup +76} and 1167{sub −74}{sup +69} K, in line with a trend that hot Jupiters all have similar nightside temperatures. We infer a Bond albedo of 0.12{sub −0.16}{sup +0.14} and a moderate day–night heat recirculation efficiency, similar to HD 209458b. General circulation models for HD 209458b and WASP-43b predict that their bright spots should be shifted east of the substellar point by tens of degrees, and these predictions were previously confirmed with Spitzer full-orbit phase curve observations. The phase curves of Qatar-1b are likewise expected to exhibit eastward offsets. Instead, the observed phase curves are consistent with no offset: 11° ± 7° at 3.6 μm and −4° ± 7° at 4.5 μm. The discrepancy in circulation patterns between these three otherwise similar planets points to the importance of secondary parameters like rotation rate and surface gravity, and the presence or absence of clouds, in determining atmospheric conditions on hot Jupiters.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Imaging Polarization of the Blue-excess Hot Dust-obscured Galaxy WISE J011601.41–050504.0

We report on VLT/FORS2 imaging polarimetry observations in the R Special band of WISE J011601.41–050504.0 (W0116–0505), a heavily obscured hyperluminous quasar at z = 3.173 classified as a Hot Dust-obscured Galaxy (Hot DOG) based on its mid-IR colors. Recently, Assef et al. identified W0116–0505 as having excess rest-frame optical/UV emission and concluded that this excess emission is most likely scattered light from the heavily obscured AGN. We find that the broadband rest-frame UV flux is strongly linearly polarized (10.8% ± 1.9%, with a polarization angle of 74° ± 9°), confirming this conclusion. We analyze these observations in the context of a simple model based on scattering either by free electrons or by optically thin dust, assuming a classical dust torus with polar openings. Both can replicate the degree of polarization and the luminosity of the scattered component for a range of geometries and column densities, but we argue that optically thin dust in the ISM is the more likely scenario. We also explore the possibility that the scattering medium corresponds to an outflow recently identified for W0116–0505. This is a feasible option if the outflow component is biconical with most of the scattering occurring at the base of the receding outflow. In this scenario, the quasar would still be obscured even if viewed face-on but might appear as a reddened type 1 quasar once the outflow has expanded. We discuss a possible connection between blue-excess Hot DOGs, extremely red quasars, reddened type 1 quasars, and unreddened quasars that depends on a combination of evolution and viewing geometry.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Hot QCD White Paper

Hot QCD physics studies the nuclear strong force under extreme temperature and densities. Experimentally these conditions are achieved via high-energy collisions of heavy ions at the Relativistic Heavy Ion Collider (RHIC) and the Large Hadron Collider (LHC). In the past decade, a unique and substantial suite of data was collected at RHIC and the LHC, probing hydrodynamics at the nucleon scale, the temperature dependence of the transport properties of quark-gluon plasma, the phase diagram of nuclear matter, the interaction of quarks and gluons at different scales and much more. This document, as part of the 2023 nuclear science long range planning process, was written to review the progress in hot QCD since the 2015 Long Range Plan for Nuclear Science, as well as highlight the realization of previous recommendations, and present opportunities for the next decade, building on the accomplishments and investments made in theoretical developments and the construction of new detectors. Furthermore, this document provides additional context to support the recommendations voted on at the Joint Hot and Cold QCD Town Hall Meeting, which are reported in a separate document.

FOS: Physical sciences↗
DOE OSTI2022

Direct Measurements of DT Fuel Preheat from Hot Electrons in Direct-Drive Inertial Confinement Fusion

Hot electrons generated by laser-plasma instabilities degrade the performance of laser-fusion implosions by preheating the DT fuel and reducing core compression. The hot-electron energy deposition in the DT fuel has been directly measured for the first time by comparing the hard x-ray signals between DT-layered and mass-equivalent ablator-only implosions. The electron energy deposition profile in the fuel is inferred through dedicated experiments using Cu-doped payloads of varying thickness. The measured preheat energy accurately explains the areal-density degradation observed in many OMEGA implosions. This technique can be used to assess the viability of the direct-drive approach to laser fusion with respect to the scaling of hot-electron preheat with laser energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Hot Water Recirculation Systems: Designing for Success [Slides]

This presentation will focus on on-demand hot water recirculation systems and how they contribute to energy and water conservation in residential buildings. This work illustrates best practices for designing, installing, and operating these systems, drawing from research and field testing to provide practical recommendations. The ultimate goal is to reduce wait times for hot water, comply with current energy codes, and lower both energy use and greenhouse gas emissions, while improving user satisfaction. In the upcoming slides, we'll dive into case studies and explore the latest technological advancements that help achieve these objectives.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Pilgrim Hot Springs Building Dimensions and Energy Modeling

This dataset was created to model the anticipated heating load of a geothermal project in development for the historical site of Pilgrim Hot Springs, and adds to the history of geothermal studies at the site. Models include an historical building (Nun's Quarters), existing modern buildings (Caretaker's Cabin, Igloo, Visitor's Cabin, Staff Shower Hut), and planned building projects (Changing Room, Greenhouse). Modeling results were used to determine feasible geothermal system typologies. The previous study linked below ("Village of Solomon Development of Energy Efficiency Building Standards for New Construction") feeds in to this project. The dataset includes DWG drawings and AKwarm energy models (.hm2) of a subset of existing buildings at the site of Pilgrim Hot Springs. All buildings were modeled in their current state, and some were additionally modeled with improvements to the building envelope. Energy modeling results exported from AKwarm include .htm and .png images.

AKwarm↗
DOE OSTI2024

Chemical and Electrochemical Characterization of Hot–Pressed Li 6 PS 5 Cl Solid State Electrolyte: Operating Pressure–Invariant High Ionic Conductivity

Sulfide solid state electrolytes (SSE) are among the most promising materials in the effort to replace liquid electrolytes, largely due to their comparable ionic conductivities. Among the sulfide SSEs, Argyrodites (Li 6 PS 5 X, X=Cl, Br, I) further stand out due to their high theoretical ionic conductivity (~1×10 –2 S cm –1 ) and interfacial stability against reactive metal anodes such as lithium. Generally, solid state electrolyte pellets are pressed from powder feedstock at room temperature, however, pellets fabricated by cold pressing consistently result in low bulk density and high porosity, facilitating interfacial degradation reactions and allowing dendrites to propagate through the pores and grain boundaries. Here, we demonstrate the mechanical and electrochemical implications of hot-pressing standalone LPSCl SSE pellets with near-theoretical ionic conductivity, superior cycling performance, and enhanced mechanical stability. X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), and x-ray diffraction spectroscopy (XRD) analysis reveal no chemical changes to the Argyrodite surface after hot pressing up to 250°C. Furthermore, we use electrochemical impedance spectroscopy (EIS) to understand mechanical stability of Argyrodite SSE pellets as a function of externally applied pressure, demonstrating for the first time pressed standalone Argyrodite pellets with near-theoretical conductivities at external pressures below 14 MPa.

25 ENERGY STORAGE↗
DOE OSTI2025

Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

The interaction between Mg, Si, and Al 2 O 3 during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al 2 O 3 yields Mg 2 Si and either MgO + Al or MgAl 2 O 4 + Al, facilitating the reduction of Al 2 O 3 and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al 2 O 3 determined the formation of either MgO or MgAl 2 O 4 . Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg 2 Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg 2 Si and MgO at the interface but did not detect MgAl 2 O 4 . In conclusion, findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Hot-melt extrudability of amorphous solid dispersions of flubendazole-copovidone: An exploratory study of the effect of drug loading and the balance of adjuvants on extrudability and dissolution

The FDA-approved anthelmintic flubendazole has shown potential to be repositioned to treat cancer and dry macular degeneration; however, its poor water solubility limits its use. Amorphous solid dispersions may overcome this challenge, but the balance of excipients may impact the preparation method and drug release. Here, we evaluate the influence of adjuvants and drug loading on the development of an amorphous solid dispersion of flubendazole-copovidone by hot-melt extrusion. The drug, copovidone, and adjuvants (magnesium stearate and hydroxypropyl cellulose) mixtures were statistically designed, and the process was performed in a twin-screw extruder. The study showed that flubendazole and copovidone mixtures were highly extrudable, except when drug loading was high (>40%). Furthermore, magnesium stearate positively impacted the extrusion and was more effective than hydroxypropyl cellulose. The extruded materials were evaluated by modulated differential scanning calorimetry and X-ray powder diffraction, obtaining positive amorphization and physical stability results. Pair distribution function analysis indicated the presence of drug rich domains with medium-range order structure and no evidence of polymer-drug interaction. All extrudates presented faster dissolution (HCl, pH 1.2) than pure flubendazole, and both adjuvants had a notable influence on the dissolution rate. In conclusion, hot-melt extrusion may be a viable option to obtain stable flubendazole: copovidone amorphous dispersions.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Phase field modeling of discontinuous dynamic recrystallization in hot deformation of magnesium alloys

We have developed a quantitative phase field model of discontinuous dynamic recrystallization (PF-DDRX) for investigating grain structure evolution and its impact on mechanical response in magnesium alloy during hot deformation. A set of isothermal compression tests were conducted by Gleeble thermo-mechanical simulator and used to determine PF-DDRX model parameters such as critical stresses of recrystallization, activation energies of dislocation, grain boundaries and recrystallization grain nucleation. In the simulations, the experimentally measured average grain size and distribution were used to generate initial microstructures. The results show that the typical ‘necklace’ microstructures observed in DDRX forms at the earlier stage of recrystallization. The inhomogeneity of microstructures first increases rapidly and then decreases gradually and reaches a constant with the increase of dynamic recrystallization volume fraction. Both predicted grain structure and mechanical response are in good agreement with experimental results. This demonstrates that the model parameters determined by experimental data are reliable for the developed PF-DDRX model to predict the grain structure evolution and flow behavior of AZ80 magnesium alloy under hot deformation. This work presents a path to combine experiments and modeling to give quantitative prediction and minimize experimental cost.

magnesium alloy, Phase field method, dynamic recry↗
DOE OSTI2024

Hybrid additive manufacturing of AISI 316L via asynchronous powder and hot-wire laser directed energy deposition

Hybrid Additive Manufacturing (AM) offers a way to leverage the advantages of different AM technologies, enabling the efficient production of sizeable parts without compromising material properties or geometric complexity capabilities. This study presents an asynchronous hybrid Directed Energy Deposition (DED) strategy employing laser powder DED and laser hot-wire DED. AISI 316L parts comprising multiple powder and wire segments were fabricated with optional machining on AISI 316L substrates to investigate how quality is impacted by (i) alternative process sequences (laser powder DED followed by laser hot-wire DED and vice versa), (ii) machined vs. as-printed interfacial conditions, and (iii) material deposition on top vs. alongside previously built segments. Optical microscopy, X-ray computed tomography, and Vickers hardness were used to characterize the morphology and microstructure of the parts, localized porosity and lack of fusion defects, bulk density, and mechanical properties. Interfacial machining was necessary for dimensional control but promoted lack of fusion voids, resulting in a 99.71 ± 0.01% dense part. As-printed interfaces resulted in a denser part (99.82 ± 0.02%) at the expense of dimensional accuracy. The hardness of the parts with as-printed and machined interfaces was 196 ± 0.37 HV and 192 ± 0.40 HV, respectively, compared to 156 ± 1.4 HV for the substrate. Depositing powder alongside or on top of wire sections resulted in interfaces with a hardness of 217 ± 2.2 HV, compared to 185 ± 3.4 HV for the wire-powder interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure and microchemistry changes at U-10Mo fuel/AA6061 cladding interfaces with varying hot isostatic pressing conditions

Monolithic uranium - 10 wt.% molybdenum (U-10Mo) is a promising high-assay low-enriched uranium fuel system for nuclear reactors used in research, medical isotope production, and remote power applications. During manufacturing, AA6061 cladding is bonded to the U-10Mo fuel plate via hot isostatic pressing, during which diffusion and fuel/cladding chemical interaction occurs at plate edges. Furthermore, the microstructure and microchemistry changes that occur at fuel/cladding interfaces are important to understand as a function of process parameters to develop a reliable fuel fabrication process and to meet the desired specifications. Here, microstructural and microchemical changes are studied using complementary electron microscopy and atom probe tomography for two manufactured fuel plates with varied hot isostatic pressing (HIP) parameters. Results highlight that modifying thermomechanical processing parameters significantly changed the interaction layer thickness between U-10Mo and AA6061 by an order of magnitude. In addition to this the distribution and concentration of elements (i.e., Al, Si, Mg) from cladding to fuel was also investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hot deformation behavior of an industrially cast large grained low density austenitic steel

Hot compression testing was performed on specimens of an Fe–30Mn–9Al–1Si-0.9C-0.5Mo wt.% low density steel which were extracted from an industrial casting with large grain size (320 ± 50 μm). Grain boundaries act as nucleation sites for dynamic recrystallization in the present material and the large grain size results in fewer nucleation sites, which delays dynamic recrystallization to larger strains and/or higher temperatures and causes higher rates of work hardening relative to similar materials but with smaller grain sizes. Here, a relatively high activation energy for hot deformation of 470 ± 90 kJ mol –1 was determined from a Zener-Hollomon analysis of the flow stresses at different temperatures and strain rates, attributed in part to the large grain size.

36 MATERIALS SCIENCE↗