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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Fabrication of UN-Mo CERMET Nuclear Fuel Using Advanced Manufacturing Techniques

Ceramic-metallic nuclear fuels are a candidate fuel for nuclear thermal propulsion systems due to their high heat transport properties, which are necessary in very high-temperature environments. The conventional fabrication of uranium nitride–molybdenum fuel has been thoroughly studied in the past, but modern manufacturing techniques have presented a unique opportunity for further development within this field. This work demonstrates the use of advanced manufacturing techniques to produce nuclear fuel pellets composed of uranium nitride microspheres encased in a molybdenum matrix. Binder jetting is used to print molybdenum disks that are filled with uranium nitride microspheres and afterward sintered using spark plasma sintering. Two fuel pellets were fabricated to demonstrate the methodology and to provide a baseline analysis of the effects of temperature and pressure processing conditions. Characterization of the sintered fuel pellets includes detailed microstructural analysis and thermal conductivity measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Photothermal alternative to device fabrication using atomic precision advanced manufacturing techniques

The attachment of dopant precursor molecules to depassivated areas of hydrogen-terminated silicon templated with a scanning tunneling microscope (STM) has been used to create electronic devices with sub-nanometer precision, typically for quantum physics demonstrations, and to dope silicon past the solid-solubility limit, with potential applications in microelectronics and plasmonics. However, this process, which we call atomic precision advanced manufacturing (APAM), currently lacks the throughput required to develop sophisticated applications because there is no proven scalable hydrogen lithography pathway. Here, we demonstrate and characterize an APAM device workflow where STM lithography has been replaced with photolithography. An ultraviolet laser is shown to locally heat silicon controllably above the temperature required for hydrogen depassivation. STM images indicate a narrow range of laser energy density where hydrogen has been depassivated, and the surface remains well-ordered. A model for photothermal heating of silicon predicts a local temperature which is consistent with atomic-scale STM images of the photo-patterned regions. Finally, a simple device made by exposing photo-depassivated silicon to phosphine is found to have a carrier density and mobility similar to that produced by similar devices patterned by STM.

42 ENGINEERING↗
DOE OSTI2020

HYBRID MANUFACTURING TECHNIQUE USING LARGE-SCALE ADDITIVE MANUFACTURING AND COMPRESSION MOLDING FOR HIGH PERFORMANCE COMPOSITES

Additive Manufacturing (AM) or 3-D printing has moved from small-scale prototypes to large-scale functional structures. With the introduction of large-scale 3D printers into the market a new industry has been born. For the first time, we are presenting the idea of preparing large-scale 3-D printed β-stage preforms to be used in traditional compression molding (CM) manufacturing technique to prepare final functional structures. Short carbon fiber (CF) reinforced material acrylonitrile butadiene Styrene i.e. ABS with 20% CF is used in present work. It is shown that highly aligned 3D printed short carbon fiber composite maintains its orientation after compression molding. A sandwich panel is prepared to show the capability to prepare complicated parts by integrating AM and CM. Interphase of the prepared dissimilar material is also studied using SEM. Samples prepared using AM-CM integration showed 11% and 79 % improvement in tensile strength and tensile modulus respectively compared to the traditional extrusion compression molding (ECM) process.

Kumar, Vipin↗
DOE OSTI2023

Modeling and Simulation of Advanced Manufacturing Techniques using MOOSE and MALAMUTE

Advanced manufacturing techniques offer increased geometry complexity, energy and material usage efficiency improvements, and an expanded palette of materials as compared to conventional manufacturing approaches. Advanced-manufacturing-produced parts can experience wide variations in the final microstructure, and these microstructure variations significantly impact the parts’ performance. In this chapter, we present recent code developments within Multiphysics Object-Oriented Simulation Environment (MOOSE) and in the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE). Here we demonstrate applying these modeling and simulation codes to two advanced manufacturing process types: advanced sintering techniques and laser-based additive manufacturing techniques. The multiphysics and multiscale capabilities of these codes enable prediction of the microstructure evolution resulting from variations in the Advanced manufacturing process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Particulates for additive manufacturing techniques

A method of making a particulate for an additive manufacturing technique includes receiving particulate at a chemical vapor deposition (CVD) reactor, flowing a hydrocarbon gas into the CVD reactor, decomposing the hydrocarbon gas in the CVD reactor, and depositing a carbonaceous coating on the particulate using a product of the decomposed hydrocarbon gas. The coating deposited over the particulate has a reflectivity that is lower than the reflectivity the underlying particulate body to reduce an energy input requirement for purposes of fusing the particulate into a layer of an article using an additive manufacturing technique. In embodiments, the coated particulate can be received at an additive manufacturing apparatus and fused into a layer of an article as a metallic-carbon composite using a high-density energy source.

42 ENGINEERING↗
DOE OSTI2025

The Effects of Manufacturing Techniques on Neutron-Irradiated C26M Mechanical Properties

Nuclear energy provides 13% of the total energy produced globally. To further improve the safety and reliability of nuclear reactors material challenges need to be successfully resolved. C26M/FeCrAl alloy systems can improve the safety and reliability of current Generation III reactors due to the potential benefits of a stable passivation layer from the Al, which can protect against corrosion, and promising mechanical performance at boiling- and light-water reactor temperatures. However, information is limited on how manufacturing techniques affect the mechanical performance of C26M in neutron-irradiated environments. In this research, C26M specimens were manufactured using three techniques and then irradiated at the Advanced Test Reactor at Idaho National Laboratory. This research aims to bridge this gap by investigating how the manufacturing techniques affects the mechanical performance of irradiated C26M at Generation III reactor relevant temperatures.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Autonomous aerial flight path inspection using advanced manufacturing techniques

Robotic systems have shown capabilities to perform inspection tasks in dangerous and difficult-to-access environments, such as those found in different components of power plants. However, most of the current robotic inspection technology is designed for specific components. Aerial robots, commonly termed as Drones, have raised an option to inspect a wider range of structural components. Nevertheless, current aerial inspecting technology still relies on a human pilot with limited line of sight, field of view and a reduced perception as the drone flies away, which prevents performing close-quarter inspection in intricate, structurally complex and GPS-denied environments. This work introduces offline inspection path generation methods based on robotics-integrated to manufacturing techniques. One method uses computer-aided manufacturing (CAM) techniques and the other an additive manufacturing (AM) approach to generate the flight path. That is to say, the drone would fly along the path described by a 3D (Three Dimensional) printer’s extruder or a CNC (Computer Numerical Control) machining tool, enabling to fly very close the structure even in physical structures with a complex geometry. Once the trajectories are generated, they are introduced for its validation in the Gazebo robotics simulator. Simulation results demonstrate the proper performance of the method and confirm that this approach can be used for close inspection of structural components.

42 ENGINEERING↗
DOE OSTI2025

A Review of the Influence of Processing Parameters on ODS Steels Produced via Additive Manufacturing Techniques

Abstract This paper reviews current observations regarding processing conditions for oxide dispersion-strengthened steels consolidated through additive manufacturing techniques. Variations in ODS steels observed across process parameters include changes in grain size, grain texture, oxide size, density of oxides, porosity, melt pool characteristics, and mechanical properties. These properties were then compared across techniques to understand which techniques and processing conditions lead to the highest strength, ductility, and oxide density. Current literature suggests that a mix of grain types, in the form of either morphology or phase, can significantly increase the strength of printed ODS steels. Meanwhile, the most ductile samples, regardless of consolidation technique or matrix material, were made from feedstock with oxide additions located on the powder surface. Reported grain and oxide sizes were plotted against the ratio of laser power to scan speed, volumetric energy density, and normalized enthalpy. No strong correlation between these values and microstructural features was observed. The plots that were made suggest that a larger data set, more in-depth representative equations, and more defined material properties as a function of specific feedstock used are necessary to determine a value that can be correlated to the printed ODS steel microstructure.

deJong, Matthew↗
DOE OSTI2024

PRODUCTION OF GLASS-TO-METAL SEALS USING ADDITIVE MANUFACTURING TECHNIQUES

Glass-to-metal (GtM) seals are hermetic barriers between glass and metal components, often used in the electronic and vacuum industries. Creating the seals traditionally requires heating all the components to the glass melting temperature, where the glass will flow and bond to the metal. Due to the manufacturing constraints of the individual components and sealing conditions there are geometric and material restrictions. Additive manufacturing techniques were used to make GtM seals to reduce these restrictions. Hermetic, single pin seals were produced using printed metal shells, by selective laser melting (SLM), and digital light processing (DLP) printed glass preforms. Glass preforms were printed with photosensitive resin mixed with a silicate sealing glass powder in a 1:2 weight ratio. Thermal analysis, TGA/DSC, and screening experiments were used to determine an organic removal schedule. Video techniques determined a sintering schedule by producing a densification curve at different isothermal holds which were fit with a viscous sintering model. Single pin seals were also produced use a laser assisted manufacturing (LAM) process as an alternative to the conventional furnace sealing process. A Nd:YAG laser was focused on a solid glass preform, heating the glass to form the glass-metal bond. The sealing glass was doped with a transition metal oxide, Fe2O3 or CuO, to increase absorption of the laser wavelength. The interface of hermetic LAM seals were analyzed using electron microscopy, compared to conventional prepared seals, finding a reduction of interfacial morphologies.

Read, Aaron Reece↗
DOE OSTI2021

Solid State Ionics: Materials Development by Multiscale Modeling and Advanced Manufacturing Techniques

Solid-state ionic materials are an important enabling technology for energy conversion and storage. Solid-state batteries would be a safer and higher energy density alternative to commercially available lithium ion batteries (LIB), however their implementation requires ion conduction in solids at room temperature to occur on the same level as the current generation of liquid electrolytes. Microstructural modifications have been demonstrated to play a major role on ion transport through the control of grain boundary interfaces, which traditionally serve as “blocking” layers. Ultimately, these materials will be fabricated in thin films form as electrolytes in order to minimize ohmic losses in electrochemical devices. This work uses advanced manufacturing techniques in combination with theoretical modeling to implement a science-based approach in the deposition of thin films ion conductors with controlled microstructures used in ceramic energy conversion and storage devices.

25 ENERGY STORAGE↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Feasibility Study of Advanced Manufacturing Techniques and Compositions of High Entropy Alloys

In line with the objectives of Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing technologies program (AMMT), this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. While the currently qualified nuclear materials have demonstrated significant irradiation resistance at high temperatures, the community is still interested in materials that can sustain the harsh environments found in nuclear reactors for temperatures up to 1,000°C for nearly 100,000 hours. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next generation nuclear reactors due to their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear energy relevant HEAs through a detailed literature survey and developing a decision matrix with criteria for identification of HEAs with may have most impact and value for further examination.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced Manufacturing Techniques and Compositions of High Entropy Alloys for Nuclear Applications

In line with the objectives of the Department of Energy, Office of Nuclear Energy, Advanced Materials and Manufacturing Technologies (AMMT) program, this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next-generation nuclear reactors because of their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear-energy-relevant HEAs through a detailed literature survey, selected experimental work, and developing a decision matrix with criteria for the identification of HEAs that may have the most impact and value for further examination.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Photothermal alternative to device fabrication using atomic precision advanced manufacturing techniques

The attachment of dopant precursor molecules to depassivated areas of hydrogen-terminated silicon templated with a scanning tunneling microscope (STM) has been used to create electronic devices with subnanometer precision, typically for quantum physics experiments. This process, which we call atomic precision advanced manufacturing (APAM), dopes silicon beyond the solid-solubility limit and produces electrical and optical characteristics that may also be useful for microelectronic and plasmonic applications. However, scanned probe lithography lacks the throughput required to develop more sophisticated applications. In this work, we demonstrate and characterize an APAM device workflow where scanned probe lithography of the atomic layer resist has been replaced by photolithography. An ultraviolet laser is shown to locally and controllably heat silicon above the temperature required for hydrogen depassivation on a nanosecond timescale, a process resistant to under- and overexposure. STM images indicate a narrow range of energy density where the surface is both depassivated and undamaged. Modeling that accounts for photothermal heating and the subsequent hydrogen desorption kinetics suggests that the silicon surface temperatures reached in our patterning process exceed those required for hydrogen removal in temperature-programmed desorption experiments. A phosphorus-doped van der Pauw structure made by sequentially photodepassivating a predefined area and then exposing it to phosphine is found to have a similar mobility and higher carrier density compared with devices patterned by STM. Lastly, it is also demonstrated that photodepassivation and precursor exposure steps may be performed concomitantly, a potential route to enabling APAM outside of ultrahigh vacuum.

nanoscale devices↗
DOE OSTI2023

Strategic Plan: Decrease Critical Minerals Waste Through Enabling Advanced Manufacturing Techniques

In this report we developed a strategic outlook derived from previous findings by our Phase-2 Scorecard Report and the Critical Mineral Evaluation Report. In addition, Phase 2 Materials Scorecards have been developed in 2022 to provide a detailed justification and traceability for the adoption of additively manufactured structural materials and ceramics for nuclear deployment. The report provides a strategic vision to harvest the benefits of reduced material and energy demands by enhanced deployment of advanced manufacturing in nuclear technology. The objective of this report is to address the needs for imminent experimental/computational studies to optimize the deployment of advanced manufacturing for its energy-, cost-, and critical materials saving potentials. We display what further actions are needed to minimize supply risks of critical minerals and to lower the economic vulnerability when implementing the additional nuclear capacity projected by 2050, in support of the U.S. goal of net-zero carbon emission. The critical minerals essential for Gen-IV nuclear technology show either low disruption potential (supply risks) combined with high economic vulnerability, such as: copper, nickel, and chromium; or low supply risks combined with medium economic vulnerability, such as: manganese, molybdenum, tungsten, vanadium, tantalum, and zirconium. Enhancements in quality and yield of critical mineral recycling and the recovery of critical minerals from solid and industrial waste streams are needed to enhance supply security for stainless-steel production and to shift the time to scarcity for society to future years.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Prefabricated Zero Ascend Omnispecies (ZAO) Modular Fish Passage Modules Using Advanced Manufacturing Techniques

The Zero Ascend Omnispecies (ZAO) fish passage attraction module “ZAO Attractor” is a novel system designed to facilitate upstream passage for a broad spectrum of fish species, with a particular focus on American shad and river herring (alewife and/or blueback herring). Combining the use of prefabricated, modular components with advanced manufacturing, the ZAO aims to provide a cost-effective and scalable solution for fish passage attractions across various hydropower sites. The system features a surface level entry, so fish do not need to climb. In addition, it is designed to be adjusted and repositioned to create the most effective attraction flows by managing the outflows from hydropower turbines. Budget Period 1 (BP1) focused on the design and modeling of the ZAO Attractor and demonstrated the engineering feasibility of a modular, prefabricated, hydrodynamically efficient structure with surface level entry and passage. It was discovered that there were limited published studies on the direct correlation between quantified flow patterns and fish attraction, emphasizing the need for controlled studies to observe and measure these effects. In Budget Period 2 (BP2), controlled studies with live fish were prioritized to address these complexities. In conclusion, the ZAO fish passage attraction module presents a promising approach to fish passage at hydropower stations, with the potential to balance environmental concerns with renewable energy development. However, further field validation and optimization are necessary to ensure its effectiveness and practicality in real-world applications.

13 HYDRO ENERGY↗
DOE OSTI2023

Ultrafast materials synthesis and manufacturing techniques for emerging energy and environmental applications

Energy and environmental issues have attracted increasing attention globally, where sustainability and low-carbon emissions are seriously considered and widely accepted by government officials. In response to this situation, the development of renewable energy and environmental technologies is urgently needed to complement the usage of traditional fossil fuels. While a big part of advancement in these technologies relies on materials innovations, new materials discovery is limited by sluggish conventional materials synthesis methods, greatly hindering the advancement of related technologies. To address this issue, this review introduces and comprehensively summarizes emerging ultrafast materials synthesis methods that could synthesize materials in times as short as nanoseconds, significantly improving research efficiency. We discuss the unique advantages of these methods, followed by how they benefit individual applications for renewable energy and the environment. We also highlight the scalability of ultrafast manufacturing towards their potential industrial utilization. Finally, we provide our perspectives on challenges and opportunities for the future development of ultrafast synthesis and manufacturing technologies. Here, we anticipate that fertile opportunities exist not only for energy and the environment but also for many other applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗